Reduced-carbon footprint concrete compositions

ABSTRACT

Reduced-carbon footprint concrete compositions, and methods for making and using the same, are provided. Aspects of the reduced-carbon footprint concrete compositions include CO 2 -sequestering carbonate compounds, which may be present in the hydraulic cement and/or aggregate components of the concrete. The reduced-carbon footprint concrete compositions find use in a variety of applications, including use in a variety of building materials and building applications.

CROSS-REFERENCE

This application is a continuation-in-part application of U.S. patentapplication Ser. No. 12/571,398, filed 30 Sep. 2009, titled“CO₂-Sequestering Formed Building Materials,” which claims the benefitof U.S. Provisional Patent Application No. 61/101,631, filed 30 Sep.2008, titled “CO₂ Sequestration”; U.S. Provisional Patent ApplicationNo. 61/110,489, filed 31 Oct. 2008, titled “CO₂-Sequestering FormedBuilding Materials”; U.S. Provisional Patent Application No. 61/149,610,filed 3 Feb. 2009, titled “CO₂-Sequestering Formed Building Materials”;and U.S. Provisional Patent Application No. 61/246,042, filed 25 Sep.2009, titled “CO₂-Sequestering Formed Building Materials,” each of isincorporated herein by reference, and to each of which we claimpriority. This application also claims the benefit of U.S. ProvisionalPatent Application No. 61/107,645, filed 22 Oct. 2008, titled“Low-Carbon Footprint Carbon Compositions”; U.S. Provisional PatentApplication No. 61/116,141, filed 19 Nov. 2008, titled “Low-CarbonFootprint Carbon Compositions”; U.S. Provisional Patent Application No.61/117,542, filed 24 Nov. 2008, titled “Low-Carbon Footprint CarbonCompositions”; U.S. Provisional Patent Application No. 61/148,353, filed29 Jan. 2009, titled “Low-Carbon Footprint Carbon Compositions”; U.S.Provisional Patent Application No. 61/149,640, filed 3 Feb. 2009, titled“Low-Carbon Footprint Carbon Compositions”; U.S. Provisional PatentApplication No. 61/225,880, filed 15 Jul. 2009, titled “Low-CarbonFootprint Carbon Compositions”; U.S. Provisional Patent Application No.61/234,251, filed 14 Aug. 2009, titled “Methods and Systems for TreatingIndustrial Waste,” each of which is incorporated herein by reference,and to each of which we claim priority.

BACKGROUND

Concrete is the most widely used engineering material in the world. Itis estimated that the present world consumption of concrete is 11billion metric tons per year. (Concrete, Microstructure, Properties andMaterials (2006, McGraw-Hill)). Concrete is a term that refers to acomposite material of a binding medium having particles or fragments ofaggregate embedded therein. In most construction concretes currentlyemployed, the binding medium is formed from a mixture of a hydrauliccement and water.

Most hydraulic cements employed today are based upon Portland cement.Portland cement is made primarily from limestone, certain clay minerals,and gypsum, in a high temperature process that drives off carbon dioxideand chemically combines the primary ingredients into new compounds. Theenergy required to fire the mixture consumes about 4 GJ per ton ofcement produced.

Because carbon dioxide is generated by both the cement productionprocess itself, as well as by energy plants that generate power to runthe production process, cement production is currently a leading sourceof current carbon dioxide atmospheric emissions. It is estimated thatcement plants account for 5% of global emissions of carbon dioxide. Asglobal warming and ocean acidification become an increasing problem andthe desire to reduce carbon dioxide gas emissions (a principal cause ofglobal warming) continues, the cement production industry will fallunder increased scrutiny.

Fossil fuels that are employed in cement plants include coal, naturalgas, oil, used tires, municipal waste, petroleum coke and biofuels.Fuels are also derived from tar sands, oil shale, coal liquids, and coalgasification and biofuels that are made via syngas. Cement plants are amajor source of CO₂ emissions, from both the burning of fossil fuels andthe CO₂ released from the calcination which changes the limestone, shaleand other ingredients to Portland cement. Cement plants also producewasted heat. Additionally, cement plants produce other pollutants likeNOx, SOx, VOCs, particulates and mercury. Cement plants also producecement kiln dust (CKD), which must sometimes be land filled, often inhazardous materials landfill sites.

Carbon dioxide (CO₂) emissions have been identified as a majorcontributor to the phenomenon of global warming and ocean acidification.CO₂ is a by-product of combustion and it creates operational, economic,and environmental problems. It is expected that elevated atmosphericconcentrations of CO₂ and other greenhouse gases will facilitate greaterstorage of heat within the atmosphere leading to enhanced surfacetemperatures and rapid climate change. CO₂ has also been interactingwith the oceans driving down the pH toward 8.0. CO₂ monitoring has shownatmospheric CO₂ has risen from approximately 280 parts per million (ppm)in the 1950s to approximately 380 ppm today, and is expect to exceed 400ppm in the next decade. The impact of climate change will likely beeconomically expensive and environmentally hazardous. Reducing potentialrisks of climate change will require sequestration of CO₂.

SUMMARY

In some embodiments, the invention provides a method comprising a)producing a synthetic carbonate component from a divalentcation-containing solution and an industrial waste gas comprising CO₂and b) incorporating the synthetic carbonate component into areduced-carbon footprint concrete composition, wherein thereduced-carbon footprint concrete composition has a reduced carbonfootprint relative to an ordinary concrete composition. In someembodiments, the reduced-carbon footprint concrete composition has asmaller carbon footprint relative to an ordinary concrete composition.In some embodiments, the reduced-carbon footprint concrete compositionhas less than 75% of the carbon footprint as the ordinary concretecomposition. In some embodiments, the reduced-carbon footprint concretecomposition has less than 50% of the carbon footprint as the ordinaryconcrete composition. In some embodiments, the reduced-carbon footprintconcrete composition has less than 25% of the carbon footprint as theordinary concrete composition. In some embodiments, the reduced-carbonfootprint concrete composition has a neutral carbon footprint. In someembodiments, the reduced-carbon footprint concrete composition has anegative carbon footprint. In some embodiments, the carbon footprint ofthe reduced-carbon footprint concrete composition results from bothcarbon dioxide that is sequestered and carbon dioxide that is avoided.In some embodiments, the negative carbon footprint is less than 0 lbsCO₂/yd³ of the reduced concrete composition. In some embodiments, thenegative carbon footprint is less than 250 lbs CO₂/yd³ of the reducedconcrete composition. In some embodiments, the negative carbon footprintis less than 500 lbs CO₂/yd³ of the reduced concrete composition. Insome embodiments, the negative carbon footprint is less than 1000 lbsCO₂/yd³ of the reduced concrete composition. In some embodiments, thesynthetic carbonate component is supplementary cementitious material,fine aggregate, coarse aggregate, or reactive pozzolanic material. Insome embodiments, the synthetic carbonate component is aragonite,nesquehonite, hydromagnesite, monohydrocalcite, or a combinationthereof. In some embodiments, the synthetic carbonate component is acombination of aragonite and hydromagnesite. In some embodiments, thesynthetic carbonate component is a combination of aragonite andnesquehonite. In some embodiments, the synthetic carbonate component isa combination of nesquehonite and monohydrocalcite. In some embodiments,the synthetic carbonate component has a δ¹³C less than −10‰. In someembodiments, the synthetic carbonate component has a δ¹³C less than−20‰. In some embodiments, the synthetic carbonate component has a δ¹³Cless than −30‰.

In some embodiments, the invention provides a reduced-carbon footprintcomposition produced by a method comprising a) producing a syntheticcarbonate component from a divalent cation-containing solution and anindustrial waste gas comprising CO₂ and b) incorporating the syntheticcarbonate component into a reduced-carbon footprint concretecomposition, wherein the reduced-carbon footprint concrete compositionhas a reduced carbon footprint relative to an ordinary concretecomposition.

In some embodiments, the invention provides a composition comprisingbetween 2.5% and 50% calcium; between 2.5% and 50% magnesium; and atleast 25% carbonates, bicarbonates, or a mixture thereof. In someembodiments, the composition comprises between 2.5% and 25% calcium. Insome embodiments, the composition comprises between 5% and 10% calcium.In some embodiments, the composition comprises between 5% and 30%magnesium. In some embodiments, the composition comprises between 10%and 30% magnesium. In some embodiments, the composition comprises atleast 50% carbonates, bicarbonates, or a mixture thereof. In someembodiments, the composition comprises at least 75% carbonates,bicarbonates, or a mixture thereof. In some embodiments, the compositioncomprises aragonite, nesquehonite, hydromagnesite, monohydrocalcite, ora combination thereof. In some embodiments, the composition comprises acombination of aragonite and hydromagnesite. In some embodiments, thecomposition comprises a combination of aragonite and nesquehonite. Insome embodiments, the composition comprises a combination ofnesquehonite and monohydrocalcite.

In some embodiments, the invention provides a reduced-carbon footprintconcrete composition comprising a CO₂-sequestering component. TheCO₂-sequestering component may be a supplementary cementitious materialor an aggregate such as a coarse aggregate or a fine aggregate. In someembodiments, the reduced-carbon footprint concrete composition comprisesa CO₂-sequestering supplementary cementitious material and aCO₂-sequestering aggregate. In some embodiments, the reduced-carbonfootprint concrete composition comprises a Portland cement clinker.

In some embodiments, the invention provides a settable compositioncomprising water and a reduced-carbon footprint concrete compositioncomprising a CO₂-sequestering component. The CO₂-sequestering componentmay be a supplementary cementitious material or an aggregate such as acoarse aggregate or a fine aggregate. In some embodiments, thereduced-carbon footprint concrete composition comprises aCO₂-sequestering supplementary cementitious material and aCO₂-sequestering aggregate. In some embodiments, the reduced-carbonfootprint concrete composition comprises a Portland cement clinker.

In some embodiments, the invention provides a method of making aconcrete, the method comprising combining a hydraulic cement with aCO₂-sequestering component. The CO₂-sequestering component may be asupplementary cementitious material or an aggregate such as a coarseaggregate or a fine aggregate. In some embodiments, the reduced-carbonfootprint concrete composition comprises a CO₂-sequesteringsupplementary cementitious material and a CO₂-sequestering aggregate. Insome embodiments, the reduced-carbon footprint concrete compositioncomprises a Portland cement clinker.

In some embodiments, the invention provides a method of combining waterwith a reduced-carbon footprint concrete composition comprising aCO₂-sequestering component to produce a hydrated concrete compositionand allowing the hydrated concrete composition to set into a solidproduct. The CO₂-sequestering component may be a supplementarycementitious material or an aggregate such as a coarse aggregate or afine aggregate. In some embodiments, the reduced-carbon footprintconcrete composition comprises a CO₂-sequestering supplementarycementitious material and a CO₂-sequestering aggregate. In someembodiments, the reduced-carbon footprint concrete composition comprisesa Portland cement clinker. In some embodiments, the solid product astructural product.

DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings of which:

FIG. 1 provides a method of the invention for producing precipitationmaterial.

FIG. 2 illustrates a system of the invention for producing aprecipitation material.

FIG. 3 provides a plot of strength vs. days for a composition of theinvention.

FIG. 4 illustrates production of a precipitation material and/or cementof the invention.

FIG. 5 provides a system of the invention for producing a precipitationmaterial and/or cement.

FIG. 6 illustrates production of a precipitation material, cement,and/or concrete of the invention from power plant flue gas comprisingCO₂.

FIG. 7 provides an Fourier transform-infrared (FT-IR) plot for ordinaryPortland cement (OPC), unhydrated supplementary cementitious admixture(SCMA), and a hydrated blend comprising 20% SCMA and 80% OPC at 7 days.

FIG. 8 provides an X-ray diffractogram (XRD) for OPC and a hydratedblend comprising 20% SCMA and 80% OPC at 7 days.

FIG. 9 provides an X-ray diffractogram (XRD) for hydrated OPC,unhydrated OPC, unhydrated SCMA, and a hydrated blend comprising 20%SCMA and 80% OPC.

FIG. 10 provides scanning electron microscopy (SEM) images for hydratedOPC and a hydrated blend comprising 20% SCMA and 80% OPC.

FIG. 11 indicates SCMA of the invention is reactive.

FIG. 12 provides different morphologies for supplementary cementitiousmaterial of the invention.

DESCRIPTION

In some embodiments, the invention provides reduced-carbon footprintconcrete compositions. The reduced-carbon footprint concrete of theinvention include a component (e.g., a CO₂-sequestering component),which comprises carbonates, bicarbonates, or a combination thereof.Additional aspects of the invention include methods of making and usingthe reduced-carbon footprint concrete.

Before the invention is described in greater detail, it is to beunderstood that the invention is not limited to particular embodimentsdescribed herein as such embodiments may vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and the terminology is notintended to be limiting. The scope of the invention will be limited onlyby the appended claims. Unless defined otherwise, all technical andscientific terms used herein have the same meaning as commonlyunderstood by one of ordinary skill in the art to which this inventionbelongs.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range and any other stated or intervening value in thatstated range, is encompassed within the invention. The upper and lowerlimits of these smaller ranges may independently be included in thesmaller ranges and are also encompassed within the invention, subject toany specifically excluded limit in the stated range. Where the statedrange includes one or both of the limits, ranges excluding either orboth of those included limits are also included in the invention.

Certain ranges are presented herein with numerical values being precededby the term “about.” The term “about” is used herein to provide literalsupport for the exact number that it precedes, as well as a number thatis near to or approximately the number that the term precedes. Indetermining whether a number is near to or approximately a specificallyrecited number, the near or approximating unrecited number may be anumber, which, in the context in which it is presented, provides thesubstantial equivalent of the specifically recited number.

All publications, patents, and patent applications cited in thisspecification are incorporated herein by reference to the same extent asif each individual publication, patent, or patent application werespecifically and individually indicated to be incorporated by reference.Furthermore, each cited publication, patent, or patent application isincorporated herein by reference to disclose and describe the subjectmatter in connection with which the publications are cited. The citationof any publication is for its disclosure prior to the filing date andshould not be construed as an admission that the invention describedherein is not entitled to antedate such publication by virtue of priorinvention. Further, the dates of publication provided might be differentfrom the actual publication dates, which may need to be independentlyconfirmed.

It is noted that, as used herein and in the appended claims, thesingular forms “a,” “an,” and “the” include plural references unless thecontext clearly dictates otherwise. It is further noted that the claimsmay be drafted to exclude any optional element. As such, this statementis intended to serve as antecedent basis for use of such exclusiveterminology as “solely,” “only,” and the like in connection with therecitation of claim elements, or use of a “negative” limitation.

As will be apparent to those of skill in the art upon reading thisdisclosure, each of the individual embodiments described and illustratedherein has discrete components and features which may be readilyseparated from or combined with the features of any of the other severalembodiments without departing from the scope or spirit of the invention.Any recited method may be carried out in the order of events recited orin any other order that is logically possible. Although any methods andmaterials similar or equivalent to those described herein may also beused in the practice or testing of the invention, representativeillustrative methods and materials are now described.

In further describing the invention, the reduced-carbon footprintconcrete compositions, as well as methods and systems for theirproduction, will be described first in greater detail. Next, methods ofusing the reduced-carbon footprint concrete compositions will bereviewed further.

Reduced-Carbon Footprint Concrete Compositions

In some embodiments, the invention provides reduced-carbon footprintconcrete compositions. Reduced-carbon footprint concrete compositionsare concrete compositions that may include, for example, an ordinaryPortland cement (OPC) component but have a reduced carbon footprint ascompared to a concrete that only includes, for example, OPC as thecement component. In some embodiments, the reduced-carbon footprintconcrete compositions comprise carbon derived from a fuel used by humans(e.g., a fossil fuel). For example, reduced-carbon footprint concretecompositions according to aspects of the invention comprise carbon thatwas released in the form of CO₂ from combustion of a fossil fuel. Incertain embodiments, the carbon sequestered in a composition of theinvention (e.g., a reduced-carbon footprint concrete composition)comprises a carbonate, bicarbonate, or a mixture thereof. Therefore, incertain embodiments, reduced-carbon footprint concrete compositionsaccording to aspects of the subject invention contain carbonates,wherein at least a portion of the carbon in the carbonates may bederived from a fuel used by humans (e.g., a fossil fuel). As such,production of reduced-carbon footprint concrete compositions of theinvention results in the placement of CO₂ into storage-stable forms thatmay be used as, for example, components of the built environment, whichenvironment comprises man-made structures such as buildings, walls,roads, etc. As such, production of reduced-carbon footprint concretecompositions of the invention results in the prevention of CO₂ gas fromentering the atmosphere.

With respect to calculation of carbon footprint, the carbon footprint ofconcrete may be determined by multiplying the pounds per cubic yard ofeach constituent by its per pound carbon footprint, summing thesevalues, and adding 10.560 kg/yd³ (the carbon footprint of transportingone yard of concrete 20 miles on average). With respect to the OPCcomponent, assuming an average CO₂ release from Portland cementproduction of 0.86 tonnes CO₂/tonne cement (as reported for CaliforniaCement Climate Action Team), each pound of Portland cement has aproduction carbon footprint of 0.86 pounds. Assuming an averagetransportation distance of 100 miles, the transportation footprint foreach pound of Portland cement is 0.016 pounds, for a total carbonfootprint of 0.876 pounds CO₂ per pound of OPC. For purposes of carbonfootprint calculation, conventional aggregate may be assumed to have acarbon footprint of 0.043 lbs CO₂/lb aggregate, while carbon footprintof conventional supplementary cementitious materials (SCMs), e.g., flyash, slag, etc., may be assumed to be 0.045 lbs CO₂/lb conventional SCM.Compared to reference concrete comprising conventional aggregate (e.g.,sand and/or rock) and OPC as the only cement component, the magnitude ofthe carbon footprint reduction of the reduced-carbon footprint concretecompositions of the invention may be equal to or more than 25 lbsCO₂/yd³ concrete, 50 lbs CO₂/yd³ concrete, 100 lbs CO₂/yd³ concrete,more than 200 lbs CO₂/yd³ concrete, more than 300 lbs CO₂/yd³ concrete,more than 400 lbs CO₂/yd³ concrete, or more than 500 lbs CO₂/yd³concrete. For example, a reduced-carbon footprint concrete compositioncomprising OPC, 20% CO₂-sequestering SCM (e.g., SCM comprisingcarbonated, bicarbonates, or a combination thereof), and 20% fly ash mayexhibit a carbon footprint reduction of about 250 lbs CO₂/yd³ concrete,such as a reduction of 244 lbs CO₂/yd³ concrete. Such a reduced-carbonfootprint concrete composition exhibits nearly half the carbon footprintof a convention concrete composition.

These reductions in carbon footprint may be achieved with concrete mixesthat include less than 50% by weight conventional SCMs, such as lessthan 40% by weight conventional SCMs, including less than 30% by weightconventional SCMs, for example, less than 20% SCMs. The term “hydrauliccement” is employed in its conventional sense to refer to a compositionwhich sets and hardens after combining with water or a solution wherethe solvent is water, e.g., an admixture solution. Setting and hardeningof the product produced by combination of the cements of the inventionwith an aqueous liquid results from the production of hydrates that areformed from the cement upon reaction with water, where the hydrates areessentially insoluble in water.

In certain embodiments, reduced-carbon footprint concrete compositionsof the invention are carbon neutral in that they have substantially nocarbon footprint (if any) as determined using, for example, thecalculation guidelines provided above. Carbon neutral concretecompositions of the invention include those compositions that exhibit acarbon footprint of less than 50 lbs CO₂/yd³ concrete, such as less than25 lbs CO₂/yd³ concrete, including less than 10 lbs CO₂/yd³ concrete,for example, less than 5 lbs CO₂/yd³ concrete. In some embodiments, thecarbon neutral concrete compositions exhibit a carbon footprint of 0CO₂/yd³ concrete or less, such as a negative carbon footprint of lessthan (i.e., more negative than) −1 lbs CO₂/yd³ concrete, less than −2lbs CO₂/yd³ concrete, less than −3 lbs CO₂/yd³ concrete, less than −4lbs CO₂/yd³ concrete, or less than −5 lbs CO₂/yd³ concrete. For example,a concrete composition comprising OPC and mostly fine syntheticaggregate (i.e., CO₂-sequestering aggregate, which comprises carbonates,bicarbonates, or a mixture thereof) may exhibit a carbon footprintreduction of more than 500 lbs CO₂/yd³ concrete (e.g., 537 lbs CO₂/yd³concrete) such that the concrete composition may be considered carbonneutral. Such a carbon neutral concrete composition may be made to havea more negative carbon footprint by displacement (also “avoidance”) of,for example, a portion of OPC. For example, a concrete compositioncomprising 60% OPC, 20% fly ash, 20% CO₂-sequestering SCM (e.g., SCMcomprising carbonates, bicarbonates, or a mixture thereof), and aportion of fine aggregate replaced with fine synthetic aggregate (i.e.,CO₂-sequestering aggregate, which comprises carbonates, bicarbonates, ora mixture thereof) may exhibit a carbon neutral footprint or asignificantly negative carbon footprint.

In some embodiments, as above, small-carbon footprint concretes have asignificantly negative carbon footprint. In such embodiments, thenegative carbon footprint of the composition may be less than (i.e.,more negative than) −10, −25, −50, −100, −250, −500, −750, or −1000 lbsCO₂/yd³ concrete. For example, a concrete composition comprising OPC,20% CO₂-sequestering SCM (e.g., SCM comprising carbonates, bicarbonates,or a mixture thereof), 100% fine synthetic aggregate (i.e., the onlyfine synthetic aggregate is fine CO₂-sequestering aggregate, whichcomprises carbonates, bicarbonates, or a mixture thereof), 100% coarsesynthetic aggregate (i.e., the only coarse synthetic aggregate is coarseCO₂-sequestering aggregate, which comprises carbonates, bicarbonates, ora mixture thereof) may exhibit a significantly negative carbon footprintof less than −1000 lbs CO₂/yd³ concrete, for example, 1146 lbs CO₂/yd³concrete. Such concrete compositions, by virtue of displacing andthereby avoiding CO₂-producing components such as OPC may exhibit aneven greater carbon footprint reduction (i.e., an even moresignificantly negative carbon footprint). As such, concrete compositionscomprising a CO₂-sequestering component (e.g., a component comprisingcarbonates, bicarbonates, or a mixture thereof) in place of aCO₂-producing component may exhibit a significantly negative carbonfootprint reflecting a net avoidance of CO₂, wherein the carbonfootprint of the concrete compositions may be less than (i.e., morenegative than) −1000 lbs CO₂/yd³ concrete, such as −1250 lbs CO₂/yd³concrete, including −1500 lbs CO₂/yd³ concrete, for example, −1750 lbsCO₂/yd³ concrete or less. For example, a concrete composition comprisingOPC, 20% CO₂-sequestering SCM (e.g., SCM comprising carbonates,bicarbonates, or a mixture thereof), 100% fine CO₂-sequesting aggregate(i.e., the only fine aggregate is fine CO₂-sequestering aggregate, whichcomprises carbonates, bicarbonates, or a mixture thereof), 100% coarseCO₂-sequestering aggregate (i.e., the only coarse aggregate is coarseCO₂-sequestering aggregate, which comprises carbonates, bicarbonates, ora mixture thereof) may exhibit a significantly negative carbon footprintresulting from a net avoidance of CO₂, wherein the negative carbonfootprint may be, for example, 1683 lbs CO₂/yd³ concrete.

Reduced-carbon footprint concrete compositions of the invention may becharacterized by including, in some embodiments, a cement component andan aggregate component. The cement component includes some portion of aconventional hydraulic cement, such as OPC, and may or may not includeone or more conventional SCMs, e.g., fly ash, slag, etc. The aggregatecomponent includes fine and/or coarse aggregates. Aspects of theconcrete compositions include the presence of a CO₂-sequesteringcomponent (e.g., a component comprising carbonates, bicarbonates, or amixture thereof), such as a CO₂-sequestering SCM and/or aCO₂-sequestering aggregate, either fine or coarse. Each of thesecomponents is now reviewed separately in greater detail.

A substantial reduction in carbon footprint may result from usingreduced-carbon footprint concrete compositions of the invention. Forexample, a substantial carbon reduction may result from combining both acement credit (i.e., the CO₂ avoided) from offsetting the use ofordinary Portland cement and the quantity of sequestered carbon fromfossil point sources. Each ton of material comprising acarbonate/bicarbonate component (e.g., CO₂-sequestering component) ofthe invention may result in a CO₂ reduction of up to 1 ton or more, suchas 1.2 tons or more, including 1.6 tons or more, for example 2 tons ormore of CO₂. Various binary, ternary, quaternary, etc. blends comprisinga carbonate/bicarbonate (e.g., CO₂-sequestering component) of theinvention may result in such reductions. The carbonate/bicarbonatecomponent (e.g., CO₂-sequestering component) may be employed as, forexample, supplementary cementitious material (SCM) in conjunction withfly ash, slag, and/or ordinary Portland cement to produce a blendedcement with a small, neutral (i.e., approximately zero), or negativecarbon footprint. Such blended cement may also have a compressivestrength at or above 1,000 psi, including at or above 2,000 psi, e.g.,at or above, 2,500 psi in 28 days or less, e.g., 14 days or less. Assuch, a blended cement of the invention with a small, neutral, ornegative carbon footprint may produce quality concrete suitable for usein concrete pavement applications.

Reduced-carbon footprint concrete compositions comprise small-,neutral-, or negative-carbon footprint concrete compositions. In someembodiments, small-, neutral-, or negative-carbon footprint concretecompositions comprise a blended cement (e.g., CO₂-sequesteringsupplementary cementitious material (SCM) in conjunction with fly ash,slag, and/or Portland cement) and a CO₂-sequestering aggregate (e.g.,the aggregate being coarse aggregate; fine aggregate such as sand;etc.), which aggregate may be prepared from a carbonate/bicarbonatecomponent (e.g., CO₂-sequestering component) of the invention inaccordance with U.S. patent application Ser. No. 12/475,378, filed 29May 2009, which is incorporated herein by reference. Such compositionsmay include, for example, a fine aggregate (e.g., sand) that has asequestered CO₂ content of approximately 20% or more, e.g., 35% or more,including 50% or more. In some embodiments, the compressive strength ofthe small-, neutral-, or negative-carbon concrete compositions may be2,500 psi or more at 28 days, e.g., 3000 psi or more, including 4,000psi at 28 days. Some embodiments provide a negative-carbon footprintconcrete composition, which exhibits compressive strengths of 4,000 psiat 28 days. Equal early strengths (i.e., at 28 days) allow for the useof small-, neutral-, or negative-carbon footprint concrete compositionswithout negatively affecting construction schedules.

In some embodiments, the invention provides small-, neutral-, ornegative-carbon footprint concrete compositions, which not only meetstrength and early strength criteria, but also finishes like normalconcrete compositions. Blended cement-concrete compositions of theinvention behave in a fashion similar to conventional OPC-concretecompositions enabling the invention to be used in similar places and forsimilar functions. In some embodiments, blended cement-concretecompositions may be used in the invention. In some embodiments, blendedcement-concrete compositions of the invention may be used. For example,blended cement-concrete compositions may be placed into parking areas(e.g. a 5,000 square foot parking lot). Blended cement-concretecompositions, due to the higher albedo of such compositions, reducecarbon emissions via reduced lighting demands. This reduction of carbonemissions may occur over the lifetime of the blended cement-concretecompositions. For example, albedo and luminance measurements of parkingareas comprising small-, neutral-, or negative-carbon footprint concretecompositions compared to asphalt parking areas may be used to determinethe difference in lighting needed and, thus, the level of carbonreduction that may be possible due to the use of higher albedo concretecompositions of the invention. Albedo tests of such compositionsdemonstrate urban heat island reduction abilities, e.g., by 2-fold ormore, 5-fold or more, 10-fold or more, 20-fold or more.

Conventional Hydraulic Cement

One component of the compositions of the invention may be a conventionalhydraulic cement. Conventional hydraulic cements are any cements thatare not CO₂-sequestering cements (e.g., a cement comprising syntheticcarbonates, synthetic bicarbonates, or a mixture thereof), e.g., asreviewed in greater detail below. Of interest in certain embodiments asthe conventional hydraulic cement is Portland cement. The Portlandcement component may be any convenient Portland cement. As is known inthe art, Portland cements are powder compositions produced by grindingPortland cement clinker (more than 90%), a limited amount of calciumsulfate which controls the set time, and up to 5% minor constituents (asallowed by various standards). As defined by the European StandardEN197.1, Portland cement clinker is a hydraulic material which shallconsist of at least two-thirds by mass of calcium silicates (3 CaO.SiO₂and 2 CaO.SiO₂), the remainder consisting of aluminum- andiron-containing clinker phases and other compounds. The ratio of CaO toSiO₂ shall not be less than 2.0. The magnesium content (MgO) shall notexceed 5.0% by mass.” In certain embodiments, the Portland cementconstituent of the present invention may be any Portland cement thatsatisfies the ASTM Standards and Specifications of C150 (Types I-VIII)of the American Society for Testing of Materials (ASTM C50-StandardSpecification for Portland Cement). ASTM C150 covers eight types ofPortland cement, each possessing different properties, and usedspecifically for those properties.

In a given concrete composition of the invention, the amount of Portlandcement component may vary. In certain embodiments, the amount ofPortland cement in the blend ranges from 10 to 90% (w/w), such as 30 to70% (w/w) and including 40 to 60% (w/w), e.g., a blend of 80% OPC and20% CO₂-sequestering SCM (e.g., SCM comprising carbonates, bicarbonates,or a mixture thereof) of the invention.

Conventional SCMs

The cements may further include one or more supplementary cementitiouscompositions, such as fly ash, slag, etc. In certain embodiments, thecements may be blends, in that they include not only the carbonatecompound composition component but also one or more additionalcomponents that may be added to modify the properties of the cement,e.g., to provide desired strength attainment, to provide desired settingtimes, etc. Components of interest that may be present in blendedcements of the invention include, but are not limited to: blast furnaceslag, fly ash, diatomaceous earth, natural or artificial pozzolans,silica fumes, limestone, gypsum, hydrated lime, etc. The amount of suchcomponents present in a given concrete composition of the invention (ifpresent at all) may vary, and in certain embodiments the amounts ofthese components range from 1 to 50% w/w, such as 2 to 25% w/w,including 10 to 20% w/w.

CO₂-Sequestering Component

CO₂-sequestering materials (also “carbon-sequestering materials”) of theinvention include materials that contain carbonates and/or bicarbonates,which may be in combination with a divalent cation such as calciumand/or magnesium, or with a monovalent cation such as sodium. Thecarbonates and/or bicarbonates may be in solution, in solid form, or acombination of solution and solid form (e.g., a slurry). The carbonatesand/or bicarbonates may contain carbon dioxide from a source of carbondioxide; in some embodiments, the carbon dioxide originates from theburning of fossil fuel, and thus, some (e.g., at least 10, 50, 60, 70,80, 90, 95%) or substantially all (e.g., at least 99, 99.5, or 99.9%) ofthe carbon in the carbonates and/or bicarbonates is of fossil fuelorigin (i.e., of plant origin). As is known, carbon of plant origin hasa different ratio of stable isotopes (¹³C and ¹²C) than carbon ofinorganic origin, and thus the carbon in the carbonates and/orbicarbonates, in some embodiments, has a δ¹³C value of less than, e.g.,−10‰, or less than −15‰, or less than −20‰, or less than −35‰, or lessthan −30‰, or less than −35‰.

As summarized above, CO₂-sequestering components include bothsupplementary cementitious materials and aggregates, both fine andcoarse, where the CO₂-sequestering components stably store a significantamount of CO₂ in the form of carbonates, bicarbonates, or a mixturethereof. Reduced-carbon footprint concrete compositions of the inventioninclude a carbonate/bicarbonate component (e.g., CO₂-sequesteringcomponent). Such components store a significant amount of CO₂ in astorage-stable format, such that CO₂ gas may not be readily producedfrom the product and released into the atmosphere. In certainembodiments, the carbonate/bicarbonate components (e.g.,CO₂-sequestering components) can store 50 tons or more of CO₂, such as100 tons or more of CO₂, including 250 tons or more of CO₂, for instance500 tons or more of CO₂, such as 750 tons or more of CO₂, including 900tons or more of CO₂ for every 1000 tons of reduced-carbon footprintconcrete composition of the invention. In certain embodiments, thecarbonate/bicarbonate components (e.g., CO₂-sequestering componentscomprises) of the reduced-carbon footprint concrete compositionscomprise about 5% or more of CO₂, such as about 10% or more of CO₂,including about 25% or more of CO₂, for instance about 50% or more ofCO₂, such as about 75% or more of CO₂, including about 90% or more ofCO₂ (e.g., present as one or more carbonate compounds).

The carbonate/bicarbonate components (e.g., CO₂-sequestering components)of the invention may include one or more carbonate compounds. The amountof carbonate in the carbonate/bicarbonate component (e.g.,CO₂-sequestering component), as determined by, for example, coulometryusing the protocol described in coulometric titration, may be 40% orhigher, such as 70% or higher, including 80% or higher. In someembodiments, where the Mg source is a mafic mineral (described in U.S.patent application Ser. No. 12/501,217, filed 10 Jul. 2009, and U.S.Provisional Patent Application No. 61/079,790, filed 10 Jul. 2008, eachof which is incorporated herein by reference) or an ash (described inU.S. patent application Ser. No. 12/486,692, filed 17 Jun. 2009, andU.S. Provisional Application No. 61/073,319, filed 17 Jun. 2008, each ofwhich is incorporated herein by reference), the resultant product may bea composition containing silica as well as carbonate. In theseembodiments, the carbonate content of the product may be as low as 10%.In some of these embodiments, the silica content of the product mayprovide improved performance as a cement or supplementary cementitiousmaterial.

The CO₂-sequestering component (e.g., precipitation material comprisingcarbonates, bicarbonates, or a mixture thereof) of reduced-carbonfootprint concrete compositions of the invention provides for long-termstorage of CO₂ in a manner such that CO₂ is sequestered (i.e., fixed) inthe reduced-carbon footprint concrete compositions, where thesequestered CO₂ does not become part of the atmosphere. Whenreduced-carbon footprint concrete compositions are maintained underconditions conventional for their intended use, reduced-carbon footprintconcrete compositions keep sequestered CO₂ fixed for extended periods oftime (e.g., 1 year or longer, 5 years or longer, 10 years or longer, 25years or longer, 50 years or longer, 100 years or longer, 250 years orlonger, 1000 years or longer, 10,000 years or longer, 1,000,000 years orlonger, or even 100,000,000 years or longer) without significant, ifany, release of the CO₂ from the reduced-carbon footprint concretecompositions. With respect to the reduced-carbon footprint concretecompositions, when employed for their intended use, the amount ofdegradation, if any, over the lifetime of the reduced-carbon footprintconcrete compositions, as measured in terms of CO₂ gas release, will notexceed 5% per year, and in certain embodiments will not exceed 1% peryear. Indeed, reduced-carbon footprint concrete compositions provided bythe invention do not release more than 1%, 5%, or 10% of their total CO₂when exposed to normal conditions of temperature and moisture, includingrainfall of normal pH, for their intended use, for at least 1, 2, 5, 10,or 20 years, or for more than 20 years, for example, for more than 100years. In some embodiments, reduced-carbon footprint concretecompositions do not release more than 1% of their total CO₂ when exposedto normal conditions of temperature and moisture, including rainfall ofnormal pH, for their intended use, for at least 1 year. In someembodiments, reduced-carbon footprint concrete compositions do notrelease more than 5% of their total CO₂ when exposed to normalconditions of temperature and moisture, including rainfall of normal pH,for their intended use, for at least 1 year. In some embodiments,reduced-carbon footprint concrete compositions do not release more than10% of their total CO₂ when exposed to normal conditions of temperatureand moisture, including rainfall of normal pH, for their intended use,for at least 1 year. In some embodiments, reduced-carbon footprintconcrete compositions do not release more than 1% of their total CO₂when exposed to normal conditions of temperature and moisture, includingrainfall of normal pH, for their intended use, for at least 10 years. Insome embodiments, reduced-carbon footprint concrete compositions do notrelease more than 1% of their total CO₂ when exposed to normalconditions of temperature and moisture, including rainfall of normal pH,for their intended use, for at least 100 years. In some embodiments, thereduced-carbon footprint concrete compositions do not release more than1% of their total CO₂ when exposed to normal conditions of temperatureand moisture, including rainfall of normal pH, for their intended use,for at least 1000 years.

Any suitable surrogate marker or test that is reasonably able to predictsuch stability may be used. For example, an accelerated test comprisingconditions of elevated temperature and/or moderate to more extreme pHconditions is reasonably able to indicate stability over extendedperiods of time. For example, depending on the environment and intendeduse of the reduced-carbon footprint concrete composition, a sample ofthe composition may be exposed to 50, 75, 90, 100, 120, or 150° C. for1, 2, 5, 25, 50, 100, 200, or 500 days at between 10% and 50% relativehumidity, and a loss less than 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, or 50%of its carbon may be considered sufficient evidence of stability of thereduced-carbon footprint concrete composition of the invention for agiven period (e.g., 1, 10, 100, 1000, or more than 1000 years).

CO₂ content of the CO₂-sequestering component(s) (e.g., precipitationmaterial comprising carbonates, bicarbonates, or a mixture thereof) ofthe reduced-carbon footprint concrete compositions may be monitored byany suitable method (e.g., coulometry). Other conditions may be adjustedas appropriate, including pH, pressure, UV radiation, and the like,again depending on the intended or likely environment. It will beappreciated that any suitable conditions may be used that one of skillin the art would reasonably conclude would indicate the requisitestability over the indicated time period. In addition, if acceptedchemical knowledge indicates that the composition would have therequisite stability for the indicated period, this may be used as well,in addition to, or in place of actual measurements. For example, somecarbonate compounds that may be part of a reduced-carbon footprintconcrete composition of the invention (e.g., in a given polymorphicform) may be well-known geologically, and may be known to have withstoodnormal weather for decades, centuries, or even millennia, withoutappreciable breakdown, and so have the requisite stability.

Depending on the particular reduced-carbon footprint concretecomposition, the amount of CO₂-sequestering component (e.g.,precipitation material comprising carbonates, bicarbonates, or a mixturethereof) present may vary. In some instances, the amount of theCO₂-sequestering component (e.g., precipitation material comprisingcarbonates, bicarbonates, or a mixture thereof) in the reduced-carbonfootprint concrete composition ranges from 5 to 100% (w/w), such as 5 to90% (w/w), including 5 to 75% (w/w), 5 to 50% (w/w), 5 to 25% (w/w), and5 to 10% (w/w).

Reduced-carbon footprint concrete compositions have reduced carbonfootprints when compared to corresponding concrete compositions thatlack the carbonate/bicarbonate component (e.g., CO₂-sequesteringcomponent). Using any convenient carbon footprint calculator, themagnitude of carbon footprint reduction of the reduced-carbon footprintconcrete compositions of the invention as compared to correspondingconcrete compositions that lack the carbonate/bicarbonate component(e.g., CO₂-sequestering component) may be 5% or more, such as 10% ormore, including 25%, 50%, 75% or even 100% or more. In certainembodiments, the reduced-carbon footprint concrete compositions of theinvention may be carbon neutral, in that they have substantially no, ifany, calculated carbon footprint, e.g., as determined using anyconvenient carbon footprint calculator that may be relevant for aparticular concrete composition of interest. Carbon neutral concretecompositions of the invention include those compositions that exhibit acarbon footprint of 50 lbs CO₂/yd³ material or less, such as 10 lbsCO₂/yd³ material or less, including 5 lbs CO₂/yd³ material or less,where in certain embodiments the carbon neutral concrete compositionshave 0 or negative lbs CO₂/yd³ material, such as negative 1 or more,e.g., negative 3 or more lbs CO₂/yd³ concrete composition. In someinstances, the reduced-carbon footprint concrete compositions have asignificantly negative carbon footprint, e.g., −100 or more lbs CO₂/yd³or less.

CO₂-sequestering components (i.e., precipitation material comprisingcarbonates, bicarbonates, or a combination thereof) of the inventioncomprise CO₂ that otherwise would have been released into theatmosphere, most of which results from combusting fossil fuels, whichfuels are of plant origin. As such, CO₂-sequestering components of theinvention, which comprise one or more synthetic carbonates and/orbicarbonates derived from industrial CO₂, reflect the relative carbonisotope composition (δ¹³C) of the fossil fuel (e.g., coal, oil, naturalgas, or flue gas) from which the industrial CO₂ (from combustion of thefossil fuel) was derived. The relative carbon isotope composition (δ¹³C)value with units of ‰ (per mille) is a measure of the ratio of theconcentration of two stable isotopes of carbon, namely ¹²C and ¹³C,relative to a standard of fossilized belemnite (the PDB standard).

δ¹³C‰=[(¹³C/¹²C sample−¹³C/¹²C PDB standard)/(¹³C/¹²C PDBstandard)]×1000

As such, the δ¹³C value of the synthetic carbonate- and/orbicarbonate-containing precipitation material (e.g., CO₂-sequesteringcomponent) serves as a fingerprint for a CO₂ gas source, especially CO₂released from burning fossil fuel. The δ¹³C value may vary from sourceto source (i.e., fossil fuel source), but the δ¹³C value forcarbonate/bicarbonate components (e.g., CO₂-sequestering components) ofthe invention generally, but not necessarily, ranges between −9‰ to−35‰. In some embodiments, the δ¹³C value for the syntheticcarbonate-containing precipitation material may be between −1‰ and −50‰,between −5‰ and −40‰, between −5‰ and −35‰, between −7‰ and −40‰,between −7‰ and −35‰, between −9‰ and −40‰, or between −9‰ and −35‰. Insome embodiments, the δ¹³C value for the synthetic carbonate-containingprecipitation material may be less than (i.e., more negative than) −3‰,−5‰, −6‰, −7‰, −8‰, −9‰, −10‰, −11‰, −12‰, −13‰, −14‰, −15‰, −16‰, −17‰,−18‰, −19‰, −20‰, −21‰, −22‰, −23‰, −24‰, −25‰, −26‰, −27‰, −28‰, −29‰,−30‰, −31‰, −32‰, −33‰, −34‰, −35‰, −36‰, −37‰, −38‰, −39‰, −40‰, −41‰,−42‰, −43‰, −44‰, or −45‰, wherein the more negative the δ¹³C value, themore rich the synthetic carbonate-containing precipitation material isin ¹²C. Any suitable method may be used for measuring the δ¹³C value,methods including, but not limited to, mass spectrometry or off-axisintegrated-cavity output spectroscopy (off-axis ICOS).

In some embodiments, the invention provides a reduced-carbon footprintconcrete composition containing a CO₂-sequestering component comprisingcarbonates, bicarbonates, or combinations thereof, where the carbon inthe carbonates and/or bicarbonates has a δ¹³C value less than −5‰. Insome embodiments, the δ¹³C value for the reduced-carbon footprintconcrete composition may be between −1‰ and −50‰, between −5‰ and −40‰,between −5‰ and −35‰, between −7‰ and −40‰, between −7‰ and −35‰,between −9‰ and −40‰, or between −9‰ and −35‰. In some embodiments, theδ¹³C value for the reduced-carbon footprint concrete composition may beless than (i.e., more negative than) −3‰, −5‰, −6‰, −7‰, −8‰, −9‰, −10‰,−11‰, −12‰, −13‰, −14‰, −15‰, −16‰, −17‰, −18‰, −19‰, −20‰, −21‰, −22‰,−23‰, −24‰, −25‰, −26‰, −27‰, −28‰, −29‰, −30‰, −31‰, −32‰, −33‰, −34‰,−35‰, −36‰, −37‰, −38‰, −39‰, −40‰, −41‰, −42‰, −43‰, −44‰, or −45‰,wherein the more negative the δ¹³C value, the more rich the syntheticcarbonate-containing composition is in ¹²C.

The carbonate compounds of the CO₂-sequestering components may bemetastable carbonate compounds precipitated from a solution of divalentcations, such as a saltwater, as described in greater detail below. Thecarbonate compound compositions of the invention include precipitatedcrystalline and/or amorphous carbonate compounds. Specific carbonateminerals of interest include, but are not limited to: calcium carbonateminerals, magnesium carbonate minerals, and calcium magnesium carbonateminerals. Calcium carbonate minerals of interest include, but are notlimited to: calcite (CaCO₃), aragonite (CaCO₃), vaterite (CaCO₃), ikaite(CaCO₃.6H₂O), and amorphous calcium carbonate (CaCO₃.nH₂O). Magnesiumcarbonate minerals of interest include, but are not limited to:magnesite (MgCO₃), barringtonite (MgCO₃.2H₂O), nesquehonite(MgCO₃.3H₂O), lanfordite (MgCO₃.5H₂O), and amorphous magnesium calciumcarbonate (MgCO₃.nH₂O). Calcium magnesium carbonate minerals of interestinclude, but are not limited to dolomite (CaMgCO₃), huntite(CaMg₃(CO₃)₄), and sergeevite (Ca₂Mg₁₁(CO₃)₁₃.H₂O). In certainembodiments, non-carbonate compounds like brucite (Mg(OH)₂) may alsoform in combination with the minerals listed above. As indicated above,the compounds of the carbonate compound compositions may be metastablecarbonate compounds (and may include one or more metastable hydroxidecompounds) that are more stable in saltwater than in freshwater, suchthat upon contact with fresh water of any pH they dissolve andre-precipitate into other fresh water stable compounds, e.g., mineralssuch as low-Mg calcite.

The carbonate/bicarbonate components (e.g., CO₂-sequestering components)of the invention may be derived from, e.g., precipitated from, asolution of divalent cations (e.g., an aqueous solution of divalentcations)(as described in greater detail below). As thecarbonate/bicarbonate components (e.g., CO₂-sequestering components) maybe precipitated from water, they might include one or more componentsthat are present in the water from which they are derived. For example,where the solution of divalent cations is saltwater, theCO₂-sequestering product (e.g., precipitation material comprisingcarbonates, bicarbonates, or a mixture thereof) will include one or morecompounds found in the saltwater source. These compounds identify thesolid precipitations of the compositions that come from the saltwatersource, where these identifying components and the amounts thereof maybe collectively referred to herein as a saltwater source identifier. Forexample, if the saltwater source is seawater, identifying compounds thatmay be present in precipitation material include, but are not limitedto: chloride, sodium, sulfur, potassium, bromide, silicon, strontium,and the like. Any such source-identifying or “marker” elements aregenerally present in small amounts, e.g., in amounts of 20,000 ppm orless, such as amounts of 2000 ppm or less. In certain embodiments, the“marker” compound may be strontium, which may be incorporated into, forexample, an aragonite lattice, and make up 10,000 ppm or less, rangingin certain embodiments from 3 to 10,000 ppm, such as from 5 to 5000 ppm,including 5 to 1000 ppm, e.g., 5 to 500 ppm, including 5 to 100 ppm.Another “marker” compound of interest is magnesium, which may be presentin amounts of up to 20% mole substitution for calcium in carbonatecompounds. The saltwater source identifier of the compositions may varydepending on the particular saltwater source employed to produce thesaltwater-derived carbonate composition. Also of interest are isotopicmarkers that identify the water source.

In certain embodiments, the CO₂-sequestering component, which comprisescarbonates, bicarbonates, or a mixture thereof, may be a supplementarycementitious material. SCMs are those materials which, though they mayor may not be hydraulically cementitious in and of themselves, react toa degree with a hydraulic cement composition, such as Portland cement,to produce a cured material. In certain embodiments, CO₂-sequesteringSCMs (e.g., SCM comprising carbonates, bicarbonates, or a mixturethereof) may be such that each ton of the SCM stores about 0.5 tons ormore of CO₂, such as about 1 ton or more of CO₂, including about 1.2tons or more of CO₂. For example, a CO₂-sequestering SCM (e.g., SCMcomprising carbonates, bicarbonates, or a mixture thereof) of theinvention may store about 0.5 tons or more of CO₂ per ton of SCMmaterial. In other words, a CO₂-sequestering SCM (e.g., SCM comprisingcarbonates, bicarbonates, or a mixture thereof) of the invention mayhave a negative carbon footprint of −0.5 tons CO₂ per ton of material.In these embodiments, the CO₂-sequestering compound (e.g., carbonates,bicarbonates, or a combination thereof) may be present as a dryparticulate composition, e.g., powder. In certain embodiments, the dryparticulate compositions may be made up of particles having an averageparticle size ranging from 0.1 to 100 microns, such as 10 to 40 micronsas determined using any convenient particle size determination protocol,such as Multi-detector laser scattering or sieving (i.e. <38 microns).In certain embodiments, multimodal, e.g., bimodal or other,distributions are present. Bimodal distributions allow the surface areato be minimized, thus allowing a lower liquids/solids mass ration forthe cement yet providing smaller reactive particles for early reaction.In these instances, the average particle size of the larger size classcan be upwards of 1000 microns (1 mm). The surface area of thecomponents making up the SCM may vary. A given cement may have anaverage surface area sufficient to provide for a liquids to solids ratioupon combination with a liquid to produce a settable composition (e.g.,as described in greater detail below) ranging from 0.5 m²/gm to 50m²/gm, such as 0.75 to 20 m²/gm and including 0.80 to 10 m²/gm. Incertain embodiments, the surface area of the cement ranges from 0.9 to 5m²/gm, such as 0.95 to 2 m²/gm and including 1 to 2 m²/gm, as determinedusing the surface area determination protocol described in Breunner,Emmit, and Teller (1953).

When present, the amount of CO₂-sequestering SCM (e.g., SCM comprisingcarbonates, bicarbonates, or a mixture thereof) in the concretecomposition may vary. In certain embodiments, the concrete includes from5 to 50% w/w, such as 5 to 25% w/w, including 5 to 10% w/w 10% to 25%w/w of CO₂-sequestering SCM (e.g., SCM comprising carbonates,bicarbonates, or a mixture thereof). In certain embodiments, thecarbonate compound composition makes up greater than 50% of the cement.

Instead of, or in addition to, a CO₂-sequestering SCM, the concretecompositions may include one or more types of CO₂-sequesteringaggregates (e.g., aggregates comprising carbonates, bicarbonates, or amixture thereof), which may be fine aggregates, coarse aggregates, etc.The term aggregate is used herein in its art accepted manner to refer toa particulate composition that finds use in concretes, mortars and othermaterials, e.g., as defined above. Aggregates of the invention may beparticulate compositions that may be classified as fine or coarse. Fineaggregates according to embodiments of the invention are particulatecompositions that almost entirely pass through a Number 4 sieve (ASTM C125 and ASTM C 33). Fine aggregate compositions according to embodimentsof the invention (which may be referred to as “sands”) have an averageparticle size ranging from 0.001 in to 0.25 in, such as 0.05 in to 0.125in and including 0.01 in to 0.08 in. As such, fine aggregate may be usedas a replacement for sand in concrete compositions. Coarse aggregates ofthe invention are compositions that are predominantly retained on aNumber 4 sieve (ASTM C 125 and ASTM C 33). Coarse aggregate compositionsaccording to embodiments of the invention are compositions that have anaverage particle size ranging from 0.125 in to 6 in, such as 0.187 in to3.0 in and including 0.25 in to 1.0 in. As such, coarse aggregate may beused as a replacement for conventional aggregate in concretecompositions.

In some embodiments, CO₂-sequestering aggregates (i.e., syntheticaggregates comprising carbonates, bicarbonates, or a mixture thereof) ofthe invention may be such that each ton of the aggregate stores about0.5 tons or more of CO₂, such as about 1 ton or more of CO₂, includingabout 1.2 tons or more of CO₂. For example, a CO₂-sequestering aggregate(e.g., aggregate comprising carbonates, bicarbonates, or a mixturethereof) of the invention may store about 0.5 tons or more of CO₂ perton of material. In other words, a CO₂-sequestering aggregate (e.g.,aggregate comprising carbonates, bicarbonates, or a mixture thereof) ofthe invention may have a negative carbon footprint of −0.5 tons CO₂ perton of material. In addition, aggregates of the invention have a densitythat may vary so long as the aggregate provides the desired propertiesto the building material in which it is employed. In certain instances,the density of the aggregates ranges from 1.1 to 5 gm/cc, such as 1.5gm/cc to 3.15 gm/cc, and including 1.8 gm/cc to 2.7 gm/cc. The hardnessof the aggregate particles making up the aggregate compositions of theinvention may also vary, and in certain instances the Mohr's hardnessranges from 1.5 to 9, such as 2 to 7, including 4 to 5.

The weight ratio of the cement component (e.g., clinker and SCM) to theaggregate component, e.g., fine and coarse aggregate, may vary. Incertain embodiments, the weight ratio of cement component to aggregatecomponent in the dry concrete component ranges from 1:10 to 4:10, suchas 2:10 to 5:10 and including from 55:1000 to 70:100.

The CO₂-sequestering aggregates of the invention, which comprisecarbonates, bicarbonates, or a mixture thereof, include one or morecarbonate compounds, e.g., as described above, and further described inU.S. Provisional Application No. 61/056,972.

Admixtures

In certain embodiments, the cements may be employed with one or moreadmixtures. In some embodiments, the cements may be employed with one ormore CO₂-sequestering admixtures. Admixtures are compositions added toconcrete to provide it with desirable characteristics that may notobtainable with basic concrete mixtures or to modify properties of theconcrete to make it more readily useable or more suitable for aparticular purpose or for cost reduction. As is known in the art, anadmixture may be any material or composition, other than the hydrauliccement, aggregate and water, that is used as a component of the concreteor mortar to enhance some characteristic, or lower the cost, thereof.The amount of admixture that is employed may vary depending on thenature of the admixture. In certain embodiments, the amounts of thesecomponents, which include synthetic admixtures, range from 1 to 50% w/w,such as 5 to 25% w/w, including 10 to 20% w/w, for example, 2 to 10%w/w.

Major reasons for using admixtures may be (1) to achieve certainstructural improvements in the resulting cured concrete; (2) to improvethe quality of concrete through the successive stages of mixing,transporting, placing, and curing during adverse weather or trafficconditions; (3) to overcome certain emergencies during concretingoperations; and/or (4) to reduce the cost of concrete construction. Insome instances, the desired concrete performance characteristics canonly be achieved by the use of an admixture. In some cases, using anadmixture allows for the use of less expensive construction methods ordesigns, the savings from which can more than offset the cost of theadmixture.

Admixtures of interest include finely divided mineral admixtures. Finelydivided mineral admixtures are materials in powder or pulverized formadded to concrete before or during the mixing process to improve orchange some of the plastic or hardened properties of Portland cementconcrete. The finely divided mineral admixtures can be classifiedaccording to their chemical or physical properties as: cementitiousmaterials; pozzolans; pozzolanic and cementitious materials; andnominally inert materials. A pozzolan is a siliceous or aluminosiliceousmaterial that possesses little or no cementitious value but will, in thepresence of water and in finely divided form, chemically react with thecalcium hydroxide released by the hydration of Portland cement to formmaterials with cementitious properties. Pozzolans can also be used toreduce the rate at which water under pressure is transferred throughconcrete. Diatomaceous earth, opaline cherts, clays, shales, fly ash,silica fume, volcanic tuffs, and pumicites are some of the knownpozzolans. Certain ground granulated blast-furnace slags and highcalcium fly ashes possess both pozzolanic and cementitious properties.Nominally inert materials can also include finely divided raw quartz,dolomites, limestone, marble, granite, and others. Fly ash is defined inASTM C618.

Fly ash, as well as material comprising metal silicates (e.g.,wollastonite, mafic minerals such as olivine and serpentine), may beused to produce CO₂-sequstering pozzolanic material (i.e., a syntheticadmixture), which may be used in carbon neutral or carbon negativeconcrete compositions of the invention. Such pozzolanic materials aredescribed in U.S. patent application Ser. No. 12/486,692, filed 17 Jun.2009 and U.S. patent application Ser. No. 12/501,217, filed 10 Jul.2009, each of which is incorporated herein by reference. Briefly,digestion of fly ash (e.g., by slaking) or material comprising metalsilicates generates, in addition to divalent cations, proton-removingagents, or a combination thereof, silica-based material, which, ifpresent during precipitation of carbonate compositions, may beencapsulated by calcium carbonate, magnesium carbonate, or a combinationthereof. As such, silica-based material acts as a nucleation site forprecipitation of calcium carbonate, magnesium carbonate, or a mixturethereof. Pozzolanic material prepared in this way may be passivated,which reduces the reactivity of the pozzolanic material, which may bedesired in certain embodiments. CO₂-sequestering pozzolanic material,which comprises synthetic carbonates, bicarbonates, or a mixturethereof, in carbon neutral or carbon negative concrete may range from 1to 50% w/w, such as 5 to 25% w/w, including 10 to 20% w/w, for example,2 to 10% w/w. In addition, CO₂-sequestering pozzolanic material (e.g.,pozzolanic material comprising carbonates, bicarbonates, or acombination thereof) is such that each ton of the pozzolanic materialstores 0.25 tons or more of CO₂, such as 0.5 tons or more of CO₂,including 1 ton or more of CO₂, for example, 2 tons or more of CO₂ perton of pozzolanic material. For example, a CO₂-sequestering pozzolanicmaterial (e.g., pozzolanic material comprising carbonates, bicarbonates,or a combination thereof) of the invention may store about 0.25 tons ormore of CO₂ per ton of pozzolanic material. In other words, aCO₂-sequestering pozzolanic material of the invention may have anegative carbon footprint of −0.25 tons CO₂ per ton of material.

One type of admixture of interest may be a plasticizer. Plasticizers maybe added to a concrete to provide it with improved workability for easeof placement with reduced consolidating effort and in reinforcedconcretes required to flow uniformly without leaving void space underreinforcing bars. Also of interest as admixtures are accelerators,retarders, air-entrainers, foaming agents, water reducers, corrosioninhibitors, and pigments. Accelerators are used to increase the curerate (hydration) of the concrete formulation and are of particularimportance in applications where it is desirable for the concrete toharden quickly and in low temperature applications. Retarders act toslow the rate of hydration and increase the time available to pour theconcrete and to form it into a desired shape. Retarders are ofparticular importance in applications where the concrete is being usedin hot climates. Air-entrainers are used to distribute tiny air bubblesthroughout the concrete. Air-entrainers are of particular value forutilization in regions that experience cold weather because the tinyentrained air bubbles help to allow for some contraction and expansionto protect the concrete from freeze-thaw damage. Pigments can also beadded to concrete to provide it with desired color characteristics foraesthetic purposes.

As such, admixtures of interest include, but are not limited to: setaccelerators, set retarders, air-entraining agents, defoamers,alkali-reactivity reducers, bonding admixtures, dispersants, coloringadmixtures, corrosion inhibitors, dampproofing admixtures, gas formers,permeability reducers, pumping aids, shrinkage compensation admixtures,fungicidal admixtures, germicidal admixtures, insecticidal admixtures,rheology modifying agents, finely divided mineral admixtures, pozzolans,aggregates, wetting agents, strength enhancing agents, water repellents,and any other concrete or mortar admixture or additive. When using anadmixture, the fresh cementitious composition, to which the admixtureraw materials are introduced, may be mixed for sufficient time to causethe admixture raw materials to be dispersed relatively uniformlythroughout the fresh concrete.

Set accelerators are used to accelerate the setting and early strengthdevelopment of concrete. A set accelerator that can be used with theadmixture system can be, but is not limited to, a nitrate salt of analkali metal, alkaline earth metal, or aluminum; a nitrite salt of analkali metal, alkaline earth metal, or aluminum; a thiocyanate of analkali metal, alkaline earth metal or aluminum; an alkanolamine; athiosulfate of an alkali metal, alkaline earth metal, or aluminum; ahydroxide of an alkali metal, alkaline earth metal, or aluminum; acarboxylic acid salt of an alkali metal, alkaline earth metal, oraluminum (preferably calcium formate); a polyhydroxylalkylamine; ahalide salt of an alkali metal or alkaline earth metal (e.g., chloride).Examples of set accelerators that may be used in the present dispensingmethod include, but are not limited to, POZZOLITH®NC534, nonchloridetype set accelerator and/or RHEOCRETE®CNI calcium nitrite-basedcorrosion inhibitor, both sold under the above trademarks by BASFAdmixtures Inc. of Cleveland, Ohio.

Also of interest are set retarding admixtures. Set retarding, also knownas delayed-setting or hydration control, admixtures are used to retard,delay, or slow the rate of setting of concrete. They can be added to theconcrete mix upon initial batching or sometime after the hydrationprocess has begun. Set retarders are used to offset the acceleratingeffect of hot weather on the setting of concrete, or delay the initialset of concrete or grout when difficult conditions of placement occur,or problems of delivery to the job site, or to allow time for specialfinishing processes. Most set retarders also act as low level waterreducers and can also be used to entrain some air into concrete.Retarders that can be used include, but are not limited to an oxy-boroncompound, corn syrup, lignin, a polyphosphonic acid, a carboxylic acid,a hydroxycarboxylic acid, polycarboxylic acid, hydroxylated carboxylicacid, such as fumaric, itaconic, malonic, borax, gluconic, and tartaricacid, lignosulfonates, ascorbic acid, isoascorbic acid, sulphonicacid-acrylic acid copolymer, and their corresponding salts,polyhydroxysilane, polyacrylamide, carbohydrates and mixtures thereof.Illustrative examples of retarders are set forth in U.S. Pat. Nos.5,427,617 and 5,203,919, incorporated herein by reference. A furtherexample of a retarder suitable for use in the admixture system is ahydration control admixture sold under the trademark DELVO® by BASFAdmixtures Inc. of Cleveland, Ohio.

Also of interest as admixtures are air entrainers. The term airentrainer includes any substance that will entrain air in cementitiouscompositions. Some air entrainers can also reduce the surface tension ofa composition at low concentration. Air-entraining admixtures are usedto purposely entrain microscopic air bubbles into concrete.Air-entrainment dramatically improves the durability of concrete exposedto moisture during cycles of freezing and thawing. In addition,entrained air greatly improves concrete's resistance to surface scalingcaused by chemical deicers. Air entrainment also increases theworkability of fresh concrete while eliminating or reducing segregationand bleeding. Materials used to achieve these desired effects can beselected from wood resin, natural resin, synthetic resin, sulfonatedlignin, petroleum acids, proteinaceous material, fatty acids, resinousacids, alkylbenzene sulfonates, sulfonated hydrocarbons, vinsol resin,anionic surfactants, cationic surfactants, nonionic surfactants, naturalrosin, synthetic rosin, an inorganic air entrainer, syntheticdetergents, and their corresponding salts, and mixtures thereof. Airentrainers are added in an amount to yield a desired level of air in acementitious composition. Examples of air entrainers that can beutilized in the admixture system include, but are not limited to MB AE90, MB VR and MICRO AIR®, all available from BASF Admixtures Inc. ofCleveland, Ohio.

Also of interest as admixtures are defoamers. Defoamers are used todecrease the air content in the cementitious composition. Examples ofdefoamers that can be utilized in the cementitious composition include,but are not limited to mineral oils, vegetable oils, fatty acids, fattyacid esters, hydroxyl functional compounds, amides, phosphoric esters,metal soaps, silicones, polymers containing propylene oxide moieties,hydrocarbons, alkoxylated hydrocarbons, alkoxylated polyalkylene oxides,tributyl phosphates, dibutyl phthalates, octyl alcohols, water-insolubleesters of carbonic and boric acid, acetylenic diols, ethyleneoxide-propylene oxide block copolymers and silicones.

Also of interest as admixtures are dispersants. The term dispersant asused throughout this specification includes, among others,polycarboxylate dispersants, with or without polyether units. The termdispersant is also meant to include those chemicals that also functionas a plasticizer, water reducer such as a high range water reducer,fluidizer, antiflocculating agent, or superplasticizer for cementitiouscompositions, such as lignosulfonates, salts of sulfonated naphthalenesulfonate condensates, salts of sulfonated melamine sulfonatecondensates, beta naphthalene sulfonates, sulfonated melamineformaldehyde condensates, naphthalene sulfonate formaldehyde condensateresins for example LOMAR D® dispersant (Cognis Inc., Cincinnati, Ohio),polyaspartates, or oligomeric dispersants. Polycarboxylate dispersantscan be used, by which is meant a dispersant having a carbon backbonewith pendant side chains, wherein at least a portion of the side chainsare attached to the backbone through a carboxyl group or an ether group.Examples of polycarboxylate dispersants can be found in U.S. Pub. No.2002/0019459 A1, U.S. Pat. No. 6,267,814, U.S. Pat. No. 6,290,770, U.S.Pat. No. 6,310,143, U.S. Pat. No. 6,187,841, U.S. Pat. No. 5,158,996,U.S. Pat. No. 6,008,275, U.S. Pat. No. 6,136,950, U.S. Pat. No.6,284,867, U.S. Pat. No. 5,609,681, U.S. Pat. No. 5,494,516; U.S. Pat.No. 5,674,929, U.S. Pat. No. 5,660,626, U.S. Pat. No. 5,668,195, U.S.Pat. No. 5,661,206, U.S. Pat. No. 5,358,566, U.S. Pat. No. 5,162,402,U.S. Pat. No. 5,798,425, U.S. Pat. No. 5,612,396, U.S. Pat. No.6,063,184, U.S. Pat. No. 5,912,284, U.S. Pat. No. 5,840,114, U.S. Pat.No. 5,753,744, U.S. Pat. No. 5,728,207, U.S. Pat. No. 5,725,657, U.S.Pat. No. 5,703,174, U.S. Pat. No. 5,665,158, U.S. Pat. No. 5,643,978,U.S. Pat. No. 5,633,298, U.S. Pat. No. 5,583,183, and U.S. Pat. No.5,393,343, which are all incorporated herein by reference as if fullywritten out below. The polycarboxylate dispersants of interest includebut are not limited to dispersants or water reducers sold under thetrademarks GLENIUM® 3030NS, GLENIUMO 3200 HES, GLENIUM 3000NS® (BASFAdmixtures Inc., Cleveland, Ohio), ADVA® (W. R. Grace Inc., Cambridge,Mass.), VISCOCRETE® (Sika, Zurich, Switzerland), and SUPERFLUX® (AximConcrete Technologies Inc., Middlebranch, Ohio).

Also of interest as admixtures are alkali reactivity reducers. Alkalireactivity reducers can reduce the alkali-aggregate reaction and limitthe disruptive expansion forces that this reaction can produce inhardened concrete. The alkali-reactivity reducers include pozzolans (flyash, silica fume), blast-furnace slag, salts of lithium and barium, andother air-entraining agents.

Natural and synthetic admixtures are used to color concrete foraesthetic and safety reasons. These coloring admixtures are usuallycomposed of pigments and include carbon black, iron oxide,phthalocyanine, umber, chromium oxide, titanium oxide, cobalt blue, andorganic coloring agents.

Also of interest as admixtures are corrosion inhibitors. Corrosioninhibitors in concrete serve to protect embedded reinforcing steel fromcorrosion due to its highly alkaline nature. The high alkaline nature ofthe concrete causes a passive and noncorroding protective oxide film toform on steel. However, carbonation or the presence of chloride ionsfrom deicers or seawater can destroy or penetrate the film and result incorrosion. Corrosion-inhibiting admixtures chemically arrest thiscorrosion reaction. The materials most commonly used to inhibitcorrosion are calcium nitrite, sodium nitrite, sodium benzoate, certainphosphates or fluorosilicates, fluoroaluminites, amines and relatedchemicals.

Also of interest are dampproofing admixtures. Dampproofing admixturesreduce the permeability of concrete that have low cement contents, highwater-cement ratios, or a deficiency of fines in the aggregate. Theseadmixtures retard moisture penetration into dry concrete and includecertain soaps, stearates, and petroleum products.

Also of interest are gas former admixtures. Gas formers, or gas-formingagents, are sometimes added to concrete and grout in very smallquantities to cause a slight expansion prior to hardening. The amount ofexpansion is dependent upon the amount of gas-forming material used andthe temperature of the fresh mixture. Aluminum powder, resin soap andvegetable or animal glue, saponin or hydrolyzed protein can be used asgas formers.

Also of interest are permeability reducers. Permeability reducers areused to reduce the rate at which water under pressure is transmittedthrough concrete. Silica fume, fly ash, ground slag, natural pozzolans,water reducers, and latex can be employed to decrease the permeabilityof the concrete.

Also of interest are rheology modifying agent admixtures. Rheologymodifying agents can be used to increase the viscosity of cementitiouscompositions. Suitable examples of rheology modifier include firmedsilica, colloidal silica, hydroxyethyl cellulose, hydroxypropylcellulose, fly ash (as defined in ASTM C618), mineral oils (such aslight naphthenic), hectorite clay, polyoxyalkylenes, polysaccharides,natural gums, or mixtures thereof.

Also of interest are shrinkage compensation admixtures. The shrinkagecompensation agent which may be used in the cementitious composition mayinclude, but is not limited, to RO(AO)₁₋₁₀H, wherein R is a C₁₋₅ alkylor C₅₋₆ cycloalkyl radical and A is a C₂₋₃ alkylene radical, alkalimetal sulfate, alkaline earth metal sulfates, alkaline earth oxides,preferably sodium sulfate and calcium oxide. TETRAGUARD® is an exampleof a shrinkage reducing agent and is available from BASF Admixtures Inc.of Cleveland, Ohio.

Bacteria and fungal growth on or in hardened concrete may be partiallycontrolled through the use of fungicidal and germicidal admixtures. Themost effective materials for these purposes are polyhalogenated phenols,dialdrin emulsions, and copper compounds.

Also of interest in certain embodiments are workability improvingadmixtures. Entrained air, which acts like a lubricant, can be used as aworkability improving agent. Other workability agents are water reducersand certain finely divided admixtures.

In certain embodiments, the cements of the invention are employed withfibers, e.g., where one desires fiber-reinforced concrete. Fibers can bemade of zirconia containing materials, steel, carbon, fiberglass, orsynthetic materials, e.g., polypropylene, nylon, polyethylene,polyester, rayon, high-strength aramid, (i.e. Kevlar®), or mixturesthereof.

Preparation of Reduced-Carbon Footprint Compositions

Aspects of the invention include methods of preparing reduced-carbonfootprint concrete compositions. Reduced-carbon footprint concretecompositions may be prepared by first producing a carbonate/bicarbonatecomponent (e.g., CO₂-sequestering component [i.e., precipitationmaterial]) and then preparing reduced-carbon footprint concretecompositions from the carbonate/bicarbonate component (e.g.,CO₂-sequestering component). The carbonate/bicarbonate component (e.g.,CO₂-sequestering component) of the reduced-carbon footprint concretecompositions may be produced from a source of CO₂, a source ofproton-removing agents (and/or methods of effecting proton removal), anda source of divalent cations, each of which materials are described infurther detail immediately below.

Carbon Dioxide

Methods of the invention include contacting a volume of a solution ofdivalent cations (e.g., an aqueous solution of divalent cations) with asource of CO₂, then subjecting the resultant solution to conditions thatfacilitate precipitation. Methods of the invention further includecontacting a volume of a solution of divalent cations (e.g., an aqueoussolution of divalent cations) with a source of CO₂ while subjecting thesolution to conditions that facilitate precipitation. There may besufficient carbon dioxide in the divalent cation-containing solution toprecipitate significant amounts of carbonate-containing precipitationmaterial (e.g., from seawater); however, additional carbon dioxide maybe used. The source of CO₂ may be any convenient CO₂ source. The CO₂source may be a gas, a liquid, a solid (e.g., dry ice), a supercriticalfluid, or CO₂ dissolved in a liquid. In some embodiments, the CO₂ sourceis a gaseous CO₂ source. The gaseous stream may be substantially pureCO₂ or comprise multiple components that include CO₂ and one or moreadditional gases and/or other substances such as ash and otherparticulates. In some embodiments, the gaseous CO₂ source may be a wastegas stream (i.e., a by-product of an active process of the industrialplant) such as exhaust from an industrial plant. The nature of theindustrial plant may vary, the industrial plants including, but notlimited to, power plants, chemical processing plants, mechanicalprocessing plants, refineries, cement plants, steel plants, and otherindustrial plants that produce CO₂ as a by-product of fuel combustion oranother processing step (such as calcination by a cement plant).

Waste gas streams comprising CO₂ include both reducing (e.g., syngas,shifted syngas, natural gas, hydrogen and the like) and oxidizingcondition streams (e.g., flue gases from combustion). Particular wastegas streams that may be convenient for the invention includeoxygen-containing combustion industrial plant flue gas (e.g., from coalor another carbon-based fuel with little or no pretreatment of the fluegas), turbo charged boiler product gas, coal gasification product gas,shifted coal gasification product gas, anaerobic digester product gas,wellhead natural gas stream, reformed natural gas or methane hydrates,and the like. Combustion gas from any convenient source may be used inmethods and systems of the invention. In some embodiments, combustiongases in post-combustion effluent stacks of industrial plants such aspower plants, cement plants, and coal processing plants may be used.

Thus, the waste streams may be produced from a variety of differenttypes of industrial plants. Suitable waste streams for the inventioninclude waste streams produced by industrial plants that combust fossilfuels (e.g., coal, oil, natural gas) and anthropogenic fuel products ofnaturally occurring organic fuel deposits (e.g., tar sands, heavy oil,oil shale, etc.). In some embodiments, a waste stream suitable forsystems and methods of the invention may be sourced from a coal-firedpower plant, such as a pulverized coal power plant, a supercritical coalpower plant, a mass burn coal power plant, a fluidized bed coal powerplant; in some embodiments, the waste stream may be sourced from gas oroil-fired boiler and steam turbine power plants, gas or oil-fired boilersimple cycle gas turbine power plants, or gas or oil-fired boilercombined cycle gas turbine power plants. In some embodiments, wastestreams produced by power plants that combust syngas (i.e., gas producedby the gasification of organic matter, for example, coal, biomass, etc.)may be used. In some embodiments, waste streams from integratedgasification combined cycle (IGCC) plants may be used. In someembodiments, waste streams produced by Heat Recovery Steam Generator(HRSG) plants may be used in accordance with systems and methods of theinvention.

Waste streams produced by cement plants may also be suitable for systemsand methods of the invention. Cement plant waste streams include wastestreams from both wet process and dry process plants, which plants mayemploy shaft kilns or rotary kilns, and may include pre-calciners. Theseindustrial plants may each burn a single fuel, or may burn two or morefuels sequentially or simultaneously. Other industrial plants such assmelters and refineries may also be useful sources of waste streams thatinclude carbon dioxide.

Industrial waste gas streams may contain carbon dioxide as the primarynon-air derived component, or may, especially in the case of coal-firedpower plants, contain additional components such as nitrogen oxides(NOx), sulfur oxides (SOx), and one or more additional gases. Additionalgases and other components may include CO, mercury and other heavymetals, and dust particles (e.g., from calcining and combustionprocesses). Additional components in the gas stream may also includehalides such as hydrogen chloride and hydrogen fluoride; particulatematter such as fly ash, dusts, and metals including arsenic, beryllium,boron, cadmium, chromium, chromium VI, cobalt, lead, manganese, mercury,molybdenum, selenium, strontium, thallium, and vanadium; and organicssuch as hydrocarbons, dioxins, and PAH compounds. Suitable gaseous wastestreams that may be treated have, in some embodiments, CO₂ present inamounts of 200 ppm to 1,000,000 ppm, such as 200,000 ppm to 1000 ppm,including 200,000 ppm to 2000 ppm, for example 180,000 ppm to 2000 ppm,or 180,000 ppm to 5000 ppm, also including 180,000 ppm to 10,000 ppm.The waste streams, particularly various waste streams of combustion gas,may include one or more additional components, for example, water, NOx(mononitrogen oxides: NO and NO₂), SOx (monosulfur oxides: SO, SO₂ andSO₃), VOC (volatile organic compounds), heavy metals such as mercury,and particulate matter (particles of solid or liquid suspended in agas). Flue gas temperature may also vary. In some embodiments, thetemperature of the flue gas comprising CO₂ may be from 0° C. to 2000°C., such as from 60° C. to 700° C., and including 100° C. to 400° C.

In some embodiments, one or more additional components or co-products(i.e., products produced from other starting materials [e.g., SOx, NOx,etc.] under the same conditions employed to convert CO₂ into carbonates)may be precipitated or trapped in precipitation material formed bycontacting the waste gas stream comprising these additional componentswith a solution comprising divalent cations (e.g., alkaline earth metalions such as Ca²⁺ and Mg²⁺). Sulfates, sulfites, and the like of calciumand/or magnesium may be precipitated or trapped in precipitationmaterial (further comprising calcium and/or magnesium carbonates)produced from waste gas streams comprising SOx (e.g., SO₂). Magnesiumand calcium may react to form MgSO₄, CaSO₄, respectively, as well asother magnesium-containing and calcium-containing compounds (e.g.,sulfites), effectively removing sulfur from the flue gas stream withouta desulfurization step such as flue gas desulfurization (“FGD”). Inaddition, CaCO₃, MgCO₃, and related compounds may be formed withoutadditional release of CO₂. In instances where the solution of divalentcations contains high levels of sulfur compounds (e.g., sulfate), thesolution may be enriched with calcium and magnesium so that calcium andmagnesium are available to form carbonate compounds after, or inaddition to, formation of CaSO₄, MgSO₄, and related compounds. In someembodiments, a desulfurization step may be staged to coincide withprecipitation of carbonate-containing precipitation material, or thedesulfurization step may be staged to occur before precipitation. Insome embodiments, multiple reaction products (e.g., MgCO₃, CaCO₃, CaSO₄,mixtures of the foregoing, and the like) may be collected at differentstages, while in other embodiments a single reaction product (e.g.,precipitation material comprising carbonates, sulfates, etc.) may becollected. In step with these embodiments, other components, such asheavy metals (e.g., mercury, mercury salts, mercury-containingcompounds), may be trapped in the carbonate-containing precipitationmaterial or may precipitate separately.

A portion of the gaseous waste stream (i.e., not the entire gaseouswaste stream) from an industrial plant may be used to produceprecipitation material. In these embodiments, the portion of the gaseouswaste stream that is employed in precipitation of precipitation materialmay be 75% or less, such as 60% or less, and including 50% and less ofthe gaseous waste stream. In yet other embodiments, substantially (e.g.,80% or more) the entire gaseous waste stream produced by the industrialplant may be employed in precipitation of precipitation material. Inthese embodiments, 80% or more, such as 90% or more, including 95% ormore, up to 100% of the gaseous waste stream (e.g., flue gas) generatedby the source may be employed for precipitation of precipitationmaterial.

Although industrial waste gas offers a relatively concentrated source ofcombustion gases, methods and systems of the invention may also beapplicable to removing combustion gas components from less concentratedsources (e.g., atmospheric air), which contains a much lowerconcentration of pollutants than, for example, flue gas. Thus, in someembodiments, methods and systems encompass decreasing the concentrationof pollutants in atmospheric air by producing a stable precipitationmaterial. In these cases, the concentration of pollutants, e.g., CO₂, ina portion of atmospheric air may be decreased by 10% or more, 20% ormore, 30% or more, 40% or more, 50% or more, 60% or more, 70% or more,80% or more, 90% or more, 95% or more, 99% or more, 99.9% or more, or99.99%. Such decreases in atmospheric pollutants may be accomplishedwith yields as described herein, or with higher or lower yields, and maybe accomplished in one precipitation step or in a series ofprecipitation steps.

Divalent Cations

Methods of the invention include contacting a volume of a solution ofdivalent cations (e.g., an aqueous solution of divalent cations) with asource of CO₂ and subjecting the resultant solution to conditions thatfacilitate precipitation. In some embodiments, a volume of a solution ofdivalent cations (e.g., an aqueous solution of divalent cations) may becontacted with a source of CO₂ while subjecting the solution toconditions that facilitate precipitation. Divalent cations may come fromany of a number of different divalent cation sources depending uponavailability at a particular location. Such sources include industrialwastes, seawater, brines, hard waters, rocks and minerals (e.g., lime,periclase, material comprising metal silicates such as serpentine andolivine), and any other suitable source.

In some locations, industrial waste streams from various industrialprocesses provide for convenient sources of divalent cations (as well asin some cases other materials useful in the process, e.g., metalhydroxide). Such waste streams include, but are not limited to, miningwastes; fossil fuel burning ash (e.g., combustion ash such as fly ash,bottom ash, boiler slag); slag (e.g. iron slag, phosphorous slag);cement kiln waste; oil refinery/petrochemical refinery waste (e.g. oilfield and methane seam brines); coal seam wastes (e.g. gas productionbrines and coal seam brine); paper processing waste; water softeningwaste brine (e.g., ion exchange effluent); silicon processing wastes;agricultural waste; metal finishing waste; high pH textile waste; andcaustic sludge. Fossil fuel burning ash, cement kiln dust, and slag,collectively waste sources of metal oxides, further described in U.S.patent application Ser. No. 12/486,692, filed 17 Jun. 2009, thedisclosure of which is incorporated herein by reference. Any of thedivalent cations sources described herein may be mixed and matched forthe purpose of practicing the invention. For example, materialcomprising metal silicates (e.g. serpentine, olivine), which are furtherdescribed in U.S. patent application Ser. No. 12/501,217, filed 10 Jul.2009, which application is incorporated herein by reference, may becombined with any of the sources of divalent cations described hereinfor the purpose of practicing the invention.

In some locations, a convenient source of divalent cations forpreparation of a carbonate/bicarbonate component (e.g., CO₂-sequesteringcomponent) of the invention may be water (e.g., an aqueous solutioncomprising divalent cations such as seawater or surface brine), whichmay vary depending upon the particular location at which the inventionis practiced. Suitable solutions of divalent cations that may be usedinclude aqueous solutions comprising one or more divalent cations, e.g.,alkaline earth metal cations such as Ca²⁺ and Mg²⁺. In some embodiments,the aqueous solution of divalent cations comprises alkaline earth metalcations. In some embodiments, the alkaline earth metal cations includecalcium, magnesium, or a mixture thereof. In some embodiments, theaqueous solution of divalent cations comprises calcium in amountsranging from 50 to 50,000 ppm, 50 to 40,000 ppm, 50 to 20,000 ppm, 100to 10,000 ppm, 200 to 5000 ppm, or 400 to 1000 ppm. In some embodiments,the aqueous solution of divalent cations comprises magnesium in amountsranging from 50 to 40,000 ppm, 50 to 20,000 ppm, 100 to 10,000 ppm, 200to 10,000 ppm, 500 to 5000 ppm, or 500 to 2500 ppm. In some embodiments,where Ca²⁺ and Mg²⁺ are both present, the ratio of Ca²⁺ to Mg²⁺ (i.e.,Ca²⁺:Mg²⁺) in the aqueous solution of divalent cations may be between1:1 and 1:2.5; 1:2.5 and 1:5; 1:5 and 1:10; 1:10 and 1:25; 1:25 and1:50; 1:50 and 1:100; 1:100 and 1:150; 1:150 and 1:200; 1:200 and 1:250;1:250 and 1:500; 1:500 and 1:1000, or a range thereof. For example, insome embodiments, the ratio of Ca²⁺ to Mg²⁺ in the aqueous solution ofdivalent cations may be between 1:1 and 1:10; 1:5 and 1:25; 1:10 and1:50; 1:25 and 1:100; 1:50 and 1:500; or 1:100 and 1:1000. In someembodiments, the ratio of Mg²⁺ to Ca²⁺ (i.e., Mg²⁺:Ca²⁺) in the aqueoussolution of divalent cations may be between 1:1 and 1:2.5; 1:2.5 and1:5; 1:5 and 1:10; 1:10 and 1:25; 1:25 and 1:50; 1:50 and 1:100; 1:100and 1:150; 1:150 and 1:200; 1:200 and 1:250; 1:250 and 1:500; 1:500 and1:1000, or a range thereof. For example, in some embodiments, the ratioof Mg²⁺ to Ca²⁺ in the aqueous solution of divalent cations may bebetween 1:1 and 1:10; 1:5 and 1:25; 1:10 and 1:50; 1:25 and 1:100; 1:50and 1:500; or 1:100 and 1:1000.

The aqueous solution of divalent cations may comprise divalent cationsderived from freshwater, brackish water, seawater, or brine (e.g.,naturally occurring brines or anthropogenic brines such as geothermalplant wastewaters, desalination plant waste waters), as well as othersalines having a salinity that is greater than that of freshwater, anyof which may be naturally occurring or anthropogenic. Brackish water iswater that is saltier than freshwater, but not as salty as seawater.Brackish water has a salinity ranging from about 0.5 to about 35 ppt(parts per thousand). Seawater is water from a sea, an ocean, or anyother saline body of water that has a salinity ranging from about 35 toabout 50 ppt. Brine is water saturated or nearly saturated with salt.Brine has a salinity that is about 50 ppt or greater. In someembodiments, the water source from which divalent cations are derived isa mineral rich (e.g., calcium-rich and/or magnesium-rich) freshwatersource. In some embodiments, the water source from which divalentcations are derived may be a naturally occurring saltwater sourceselected from a sea, an ocean, a lake, a swamp, an estuary, a lagoon, asurface brine, a deep brine, an alkaline lake, an inland sea, or thelike. In some embodiments, the water source from which divalent cationare derived may be an anthropogenic brine selected from a geothermalplant wastewater or a desalination wastewater.

Freshwater may be a convenient source of divalent cations (e.g., cationsof alkaline earth metals such as Ca²⁺ and Mg²⁺). Any of a number ofsuitable freshwater sources may be used, including freshwater sourcesranging from sources relatively free of minerals to sources relativelyrich in minerals. Mineral-rich freshwater sources may be naturallyoccurring, including any of a number of hard water sources, lakes, orinland seas. Some mineral-rich freshwater sources such as alkaline lakesor inland seas (e.g., Lake Van in Turkey) also provide a source ofpH-modifying agents. Mineral-rich freshwater sources may also beanthropogenic. For example, a mineral-poor (soft) water may be contactedwith a source of divalent cations such as alkaline earth metal cations(e.g., Ca²⁺, Mg²⁺ etc.) to produce a mineral-rich water that is suitablefor methods and systems described herein. Divalent cations or precursorsthereof (e.g. salts, minerals) may be added to freshwater (or any othertype of water described herein) using any convenient protocol (e.g.,addition of solids, suspensions, or solutions). In some embodiments,divalent cations selected from Ca²⁺ and Mg²⁺ may be added to freshwater.In some embodiments, monovalent cations selected from Na+ and K+ areadded to freshwater. In some embodiments, freshwater comprising Ca²⁺ maybe combined with combustion ash (e.g., fly ash, bottom ash, boilerslag), or products or processed forms thereof, yielding a solutioncomprising calcium and magnesium cations.

In some embodiments, an aqueous solution of divalent cations may beobtained from an industrial plant that is also providing a combustiongas stream. For example, in water-cooled industrial plants, such asseawater-cooled industrial plants, water that has been used by anindustrial plant for cooling may then be used as water for producingprecipitation material. If desired, the water may be cooled prior toentering a precipitation system of the invention. Such approaches may beemployed, for example, with once-through cooling systems. For example, acity or agricultural water supply may be employed as a once-throughcooling system for an industrial plant. Water from the industrial plantmay then be employed for producing precipitation material, whereinoutput water has a reduced hardness and greater purity.

Proton-Removing Agents and Methods for Effecting Proton Removal

Methods of the invention include contacting a volume of a solution ofdivalent cations (e.g., an aqueous solution of divalent cations) with asource of CO₂ (to dissolve CO₂) and subjecting the resultant solution toconditions that facilitate precipitation. In some embodiments, a volumeof a solution of divalent cations (e.g., an aqueous solution of divalentcations) may be contacted with a source of CO₂ (to dissolve CO₂) whilesubjecting the solution to conditions that facilitate precipitation. Thedissolution of CO₂ into the solution of divalent cations producescarbonic acid, a species in equilibrium with both bicarbonate andcarbonate. To produce carbonate-containing precipitation material,protons are removed from various species (e.g. carbonic acid,bicarbonate, hydronium, etc.) in the divalent cation-containing solutionto shift the equilibrium toward carbonate. As protons are removed, moreCO₂ goes into solution. In some embodiments, proton-removing agentsand/or methods may be used while contacting a divalent cation-containingsolution (e.g., an aqueous solution comprising divalent cations) withCO₂ to increase CO₂ absorption in one phase of the precipitationreaction, wherein the pH may remain constant, increase, or evendecrease, followed by a rapid removal of protons (e.g., by addition of abase) to cause rapid precipitation of carbonate-containing precipitationmaterial. Protons may be removed from the various species (e.g. carbonicacid, bicarbonate, hydronium, etc.) by any convenient approach,including, but not limited to use of naturally occurring proton-removingagents, use of microorganisms and fungi, use of synthetic chemicalproton-removing agents, recovery of man-made waste streams, and usingelectrochemical means.

Naturally occurring proton-removing agents encompass any proton-removingagents found in the wider environment that may create or have a basiclocal environment. Some embodiments provide for naturally occurringproton-removing agents including minerals that create basic environmentsupon addition to solution. Such minerals include, but are not limitedto, lime (CaO); periclase (MgO); iron hydroxide minerals (e.g., goethiteand limonite); and volcanic ash. Methods for digestion of such mineralsand rocks comprising such minerals are provided herein. Some embodimentsprovide for using naturally alkaline bodies of water as naturallyoccurring proton-removing agents. Examples of naturally alkaline bodiesof water include, but are not limited to surface water sources (e.g.alkaline lakes such as Mono Lake in California) and ground water sources(e.g. basic aquifers such as the deep geologic alkaline aquifers locatedat Searles Lake in California). Other embodiments provide for use ofdeposits from dried alkaline bodies of water such as the crust alongLake Natron in Africa's Great Rift Valley. In some embodiments,organisms that excrete basic molecules or solutions in their normalmetabolism may be used as proton-removing agents. Examples of suchorganisms are fungi that produce alkaline protease (e.g., the deep-seafungus Aspergillus ustus with an optimal pH of 9) and bacteria thatcreate alkaline molecules (e.g., cyanobacteria such as Lyngbya sp. fromthe Atlin wetland in British Columbia, which increases pH from abyproduct of photosynthesis). In some embodiments, organisms may be usedto produce proton-removing agents, wherein the organisms (e.g., Bacilluspasteurii, which hydrolyzes urea to ammonia) metabolize a contaminant(e.g. urea) to produce proton-removing agents or solutions comprisingproton-removing agents (e.g., ammonia, ammonium hydroxide). In someembodiments, organisms may be cultured separately from the precipitationreaction mixture, wherein proton-removing agents or solutions comprisingproton-removing agents are used for addition to the precipitationreaction mixture. In some embodiments, naturally occurring ormanufactured enzymes may be used in combination with proton-removingagents to invoke precipitation of precipitation material. Carbonicanhydrase, which is an enzyme produced by plants and animals,accelerates transformation of carbonic acid to bicarbonate in solution.As such, carbonic anhydrase may be used to enhance dissolution of CO₂and accelerate precipitation of precipitation material, as described inU.S. Provisional Patent Application 61/252,929 filed 19 Oct. 2009, whichis incorporated herein by reference in its entirety.

Chemical agents for effecting proton removal generally refer tosynthetic chemical agents produced in large quantities and commerciallyavailable. For example, chemical agents for removing protons include,but are not limited to, hydroxides, organic bases, super bases, oxides,ammonia, and carbonates. Hydroxides include chemical species thatprovide hydroxide anions in solution, including, for example, sodiumhydroxide (NaOH), potassium hydroxide (KOH), calcium hydroxide(Ca(OH)2), or magnesium hydroxide (Mg(OH)₂). Organic bases arecarbon-containing molecules that are generally nitrogenous basesincluding primary amines such as methyl amine, secondary amines such asdiisopropylamine, tertiary such as diisopropylethylamine, aromaticamines such as aniline, heteroaromatics such as pyridine, imidazole, andbenzimidazole, and various forms thereof. In some embodiments, anorganic base selected from pyridine, methylamine, imidazole,benzimidazole, histidine, and a phophazene may be used to remove protonsfrom various species (e.g., carbonic acid, bicarbonate, hydronium, etc.)for precipitation of precipitation material. In some embodiments,ammonia may be used to raise pH to a level sufficient to precipitateprecipitation material from a solution of divalent cations and anindustrial waste stream. Super bases suitable for use as proton-removingagents include sodium ethoxide, sodium amide (NaNH₂), sodium hydride(NaH), butyl lithium, lithium diisopropylamide, lithium diethylamide,and lithium bis(trimethylsilyl)amide. Oxides including, for example,calcium oxide (CaO), magnesium oxide (MgO), strontium oxide (SrO),beryllium oxide (BeO), and barium oxide (BaO) may be also suitableproton-removing agents that may be used. Carbonates for use in theinvention include, but are not limited to, sodium carbonate.

In addition to comprising cations of interest and other suitable metalforms, waste streams from various industrial processes may provideproton-removing agents. Such waste streams include, but are not limitedto, mining wastes; fossil fuel burning ash (e.g., combustion ash such asfly ash, bottom ash, boiler slag); slag (e.g. iron slag, phosphorousslag); cement kiln waste; oil refinery/petrochemical refinery waste(e.g. oil field and methane seam brines); coal seam wastes (e.g. gasproduction brines and coal seam brine); paper processing waste; watersoftening waste brine (e.g., ion exchange effluent); silicon processingwastes; agricultural waste; metal finishing waste; high pH textilewaste; and caustic sludge. Mining wastes include any wastes from theextraction of metal or another precious or useful mineral from theearth. In some embodiments, wastes from mining may be used to modify pH,wherein the waste is selected from red mud from the Bayer aluminumextraction process; waste from magnesium extraction from seawater (e.g.,Mg(OH)2 such as that found in Moss Landing, Calif.); and wastes frommining processes involving leaching. For example, red mud may be used tomodify pH as described in U.S. Provisional Patent Application No.61/161,369, filed 18 Mar. 2009, which is incorporated herein byreference in its entirety. Fossil fuel burning ash, cement kiln dust,and slag, collectively waste sources of metal oxides, further describedin U.S. patent application Ser. No. 12/486,692, filed 17 Jun. 2009, thedisclosure of which is incorporated herein in its entirety, may be usedin alone or in combination with other proton-removing agents to provideproton-removing agents for the invention. Agricultural waste, eitherthrough animal waste or excessive fertilizer use, may contain potassiumhydroxide (KOH) or ammonia (NH₃) or both. As such, agricultural wastemay be used in some embodiments of the invention as a proton-removingagent. This agricultural waste is often collected in ponds, but it mayalso percolate down into aquifers, where it may be accessed and used.

Electrochemical methods may be another means to remove protons fromvarious species in a solution, either by removing protons from solute(e.g., deprotonation of carbonic acid or bicarbonate) or from solvent(e.g., deprotonation of hydronium or water). Deprotonation of solventmay result, for example, if proton production from CO₂ dissolutionmatches or exceeds electrochemical proton removal from solute molecules.In some embodiments, low-voltage electrochemical methods may be used toremove protons, for example, as CO₂ is dissolved in the precipitationreaction mixture or a precursor solution to the precipitation reactionmixture (i.e., a solution that may or may not contain divalent cations).In some embodiments, CO₂ dissolved in a solution that does not containdivalent cations may be treated by a low-voltage electrochemical methodto remove protons from carbonic acid, bicarbonate, hydronium, or anyspecies or combination thereof resulting from the dissolution of CO₂. Alow-voltage electrochemical method operates at an average voltage of 2,1.9, 1.8, 1.7, or 1.6 V or less, such as 1.5, 1.4, 1.3, 1.2, 1.1 V orless, such as 1 V or less, such as 0.9 V or less, 0.8 V or less, 0.7 Vor less, 0.6 V or less, 0.5 V or less, 0.4 V or less, 0.3 V or less, 0.2V or less, or 0.1 V or less. Low-voltage electrochemical methods that donot generate chlorine gas may be convenient for use in systems andmethods of the invention. Low-voltage electrochemical methods to removeprotons that do not generate oxygen gas may also be convenient for usein systems and methods of the invention. In some embodiments,low-voltage electrochemical methods generate hydrogen gas at the cathodeand transport it to the anode where the hydrogen gas is converted toprotons. Electrochemical methods that do not generate hydrogen gas mayalso be convenient. In some instances, electrochemical methods to removeprotons do not generate any gaseous by-byproduct. Electrochemicalmethods for effecting proton removal are further described in U.S.patent application Ser. No. 12/344,019, filed 24 Dec. 2008; U.S. patentapplication Ser. No. 12/375,632, filed 23 Dec. 2008; InternationalPatent Application No. PCT/US08/088,242, filed 23 Dec. 2008;International Patent Application No. PCT/US09/32301, filed 28 Jan. 2009;International Patent Application No. PCT/US09/48511, filed 24 Jun. 2009;and U.S. patent application Ser. No. 12/541,055, filed 13 Aug. 2009,each of which are incorporated herein by reference in their entirety.

Alternatively, electrochemical methods may be used to produce causticmolecules (e.g., hydroxide) through, for example, the chlor-alkaliprocess, or modification thereof. Electrodes (i.e., cathodes and anodes)may be present in the apparatus containing the divalentcation-containing solution or gaseous waste stream-charged (e.g.,CO₂-charged) solution, and a selective barrier, such as a membrane, mayseparate the electrodes. Electrochemical systems and methods forremoving protons may produce by-products (e.g., hydrogen) that may beharvested and used for other purposes. Additional electrochemicalapproaches that may be used in systems and methods of the inventioninclude, but are not limited to, those described in U.S. ProvisionalPatent Application No. 61/081,299, filed 16 Jul. 2008, and U.S.Provisional Patent Application No. 61/091,729, the disclosures of whichare incorporated herein by reference. Combinations of the abovementioned sources of proton-removing agents and methods for effectingproton removal may be employed.

A variety of different methods may be employed to prepare theCO₂-sequestrating component of the concretes of the invention from thesource of CO₂, the source of divalent cations, and the source ofproton-removing agents. CO₂ sequestration protocols of interest include,but are not limited to, those disclosed in U.S. patent application Ser.Nos. 12/126,776 and 12/163,205; as well as U.S. Provisional PatentApplication Nos. 61/126,776, filed 23 May 2008; 12/163,205, filed 27Jun. 2008; 12/344,019, filed 24 Dec. 2008; and 12/475,378, filed 29 May2009, as well as U.S. Provisional Patent Application Nos. 61/017,405;61/017,419; 61/057,173; 61/056,972; 61/073,319; 61/079,790; 61/081,299;61/082,766; 61/088,347; 61/088,340; 61/101,629; and 61/101,631017,405,filed 28 Dec. 2007; 61/017,419, filed 28 Dec. 2007; 61/057,173, filed 29May 2008; 61/056,972, filed 29 May 2008; 61/073,319, filed 17 Jun. 2008;61/079,790, 10 Jul. 2008; 61/081,299, filed 16 Jul. 2008; 61/082,766,filed 22 Jul. 2008; 61/088,347, filed 13 Aug. 2008; 61/088,340, filed 12Aug. 2008; 61/101,629, filed 30 Sep. 2008; and 61/101,631, filed 30 Sep.2008; each of which are incorporated herein by reference.

CO₂-sequestering components (e.g., components comprising carbonates,bicarbonates, or a combination thereof) of the invention includecarbonate compositions that may be produced by precipitating a calciumand/or magnesium carbonate composition from a solution of divalentcations. The carbonate compound compositions of the invention includeprecipitated crystalline and/or amorphous carbonate compounds. Thecarbonate compound compositions that make up the CO₂-sequesteringcomponents (e.g., components comprising carbonates, bicarbonates, or acombination thereof) of the invention include metastable carbonatecompounds that may be precipitated from a solution of divalent cations,such as a saltwater, as described in greater detail below.

For convenience, the invention herein is sometimes described in terms ofsaltwater; however, it is to be understood that any source of watercomprising divalent cations may be used. Saltwater-derived carbonatecompound compositions of the invention (i.e., compositions derived fromsaltwater and made up of one or more different carbonate crystallineand/or amorphous compounds with or without one or more hydroxidecrystalline or amorphous compounds) are derived from a saltwater. Assuch, they comprise compositions that are obtained from a saltwater insome manner, e.g., by treating a volume of a saltwater in a mannersufficient to produce the desired carbonate compound composition fromthe initial volume of saltwater. The carbonate compound compositions ofcertain embodiments may be produced by precipitation from a solution ofdivalent cations (e.g., a saltwater) that includes alkaline earth metalcations, such as calcium and magnesium, etc., where such solutions ofdivalent cations may be collectively referred to as alkaline earthmetal-containing waters.

The saltwater employed in methods may vary. As reviewed above, saltwaterof interest include brackish water, seawater and brine, as well as othersalines having a salinity that is greater than that of freshwater (whichhas a salinity of less than 5 ppt dissolved salts). In some embodiments,calcium rich waters may be combined with magnesium silicate minerals,such as olivine or serpentine, in solution that has become acidic due tothe addition on carbon dioxide to form carbonic acid, which dissolvesthe magnesium silicate, leading to the formation of calcium magnesiumsilicate carbonate compounds as mentioned above.

In methods of producing the carbonate compound compositions of theinvention, a volume of water may be subjected to carbonate compoundprecipitation conditions sufficient to produce a carbonate-containingprecipitation material and a mother liquor (i.e., the part of the waterthat is left over after precipitation of the carbonate compound(s) fromthe saltwater). The resultant precipitation material and mother liquorcollectively make up the carbonate compound compositions of theinvention. Any convenient precipitation conditions may be employed,which conditions result in the production of a carbonate compoundcomposition sequestration product.

Conditions that facilitate precipitation (i.e., precipitationconditions) may vary. For example, the temperature of the water may bewithin a suitable range for the precipitation of the desired mineral tooccur. In some embodiments, the temperature of the water may be in arange from 5 to 70° C., such as from 20 to 50° C. and including from 25to 45° C. As such, while a given set of precipitation conditions mayhave a temperature ranging from 0 to 100° C., the temperature of thewater may have to be adjusted in certain embodiments to produce thedesired precipitation material.

In normal seawater, 93% of the dissolved CO₂ may be in the form ofbicarbonate ions (HCO₃ ⁻) and 6% may be in the form of carbonate ions(CO₃ ²⁻). When calcium carbonate precipitates from normal seawater, CO₂is released. In fresh water, above pH 10.33, greater than 90% of thecarbonate is in the form of carbonate ion, and no CO₂ is released duringthe precipitation of calcium carbonate. In seawater this transitionoccurs at a slightly lower pH, closer to a pH of 9.7. While the pH ofthe water employed in methods may range from pH 5 to pH 14 during agiven precipitation process, in certain embodiments the pH may be raisedto alkaline levels in order to drive the precipitation of carbonatecompounds, as well as other compounds, e.g., hydroxide compounds, asdesired. In certain of these embodiments, the pH may be raised to alevel that minimizes if not eliminates CO₂ production duringprecipitation, causing dissolved CO₂, e.g., in the form of carbonate andbicarbonate, to be trapped in the precipitation material. In theseembodiments, the pH may be raised to 10 or higher, such as 11 or higher.

The pH of the water may be raised using any convenient approach. Incertain embodiments, a proton-removing agent may be employed, whereexamples of such agents include oxides, hydroxides (e.g., calcium oxidein fly ash, potassium hydroxide, sodium hydroxide, brucite (Mg(OH)₂,etc.), carbonates (e.g., sodium carbonate), and the like, many of whichare described above. One such approach for raising the pH of theprecipitation reaction mixture or precursor thereof (e.g., divalentcation-containing solution) is to use the coal ash from a coal-firedpower plant, which contains many oxides. Other coal processes, like thegasification of coal, to produce syngas, also produce hydrogen gas andcarbon monoxide, and may serve as a source of hydroxide as well. Somenaturally occurring minerals, such as serpentine, contain hydroxide, andmay be dissolved to yield a source of hydroxide. The addition ofserpentine, also releases silica and magnesium into the solution,leading to the formation of silica-containing precipitation material.The amount of proton-removing agent that is added to the precipitationreaction mixture or precursor thereof will depend on the particularnature of the proton-removing agent and the volume of the precipitationreaction mixture or precursor thereof being modified, and will besufficient to raise the pH of the precipitation reaction mixture orprecursor thereof to the desired pH. Alternatively, the pH of theprecipitation reaction mixture or precursor thereof may be raised to thedesired level by electrochemical means as described above. Additionalelectrochemical methods may be used under certain conditions. Forexample, electrolysis may be employed, wherein the mercury cell process(also called the Castner-Kellner process); the diaphragm cell process,the membrane cell process, or some combination thereof may be used.Where desired, byproducts of the hydrolysis product, e.g., H₂, sodiummetal, etc. may be harvested and employed for other purposes, asdesired.

In yet other embodiments, the pH-elevating approach described in U.S.Provisional Patent Application Nos. 61/081,299, filed 16 Jul. 2008, and61/091,729, filed 25 Aug. 2008, may be employed, the disclosures ofwhich are incorporated herein by reference.

Additives other than pH-elevating agents may also be introduced into thewater in order to influence the nature of the precipitation materialproduced. As such, certain embodiments of the methods include providingan additive in water before or during the time when the water issubjected to the precipitation conditions. Certain calcium carbonatepolymorphs can be favored by trace amounts of certain additives. Forexample, vaterite, a highly unstable polymorph of CaCO₃, whichprecipitates in a variety of different morphologies and converts rapidlyto calcite, may be obtained at very high yields by including traceamounts of lanthanum as lanthanum chloride in a supersaturated solutionof calcium carbonate. Other additives beside lanthanum that are ofinterest include, but are not limited to transition metals and the like.For instance, the addition of ferrous or ferric iron is known to favorthe formation of disordered dolomite (protodolomite) where it would notform otherwise.

The nature of the precipitation material can also be influenced byselection of appropriate major ion ratios. Major ion ratios also haveconsiderable influence of polymorph formation. For example, as themagnesium:calcium ratio in the water increases, aragonite becomes thefavored polymorph of calcium carbonate over low-magnesium calcite. Atlow magnesium:calcium ratios, low-magnesium calcite may be the preferredpolymorph. As such, a wide range of magnesium:calcium ratios may beemployed, including, for example, 100:1, 50:1, 20:1, 10:1, 5:1, 2:1,1:1, 1:2, 1:5, 1:10, 1:20, 1:50, 1:100, or any of the ratios mentionedabove. In certain embodiments, the magnesium:calcium ratio may bedetermined by the source of water employed in the precipitation process(e.g., seawater, brine, brackish water, fresh water), whereas in otherembodiments, the magnesium:calcium ratio may be adjusted to fall withina certain range.

Rate of precipitation also has a large effect on compound phaseformation. The most rapid precipitation may be achieved by seeding thesolution with a desired phase. Without seeding, rapid precipitation maybe achieved by rapidly increasing the pH of the seawater, which resultsin more amorphous constituents. When silica is present, the more rapidthe reaction rate, the more silica is incorporated in thecarbonate-containing precipitation material. The higher the pH is, themore rapid the precipitation is and the more amorphous the precipitationmaterial.

Accordingly, a set of precipitation conditions to produce a desiredprecipitation material from a solution of divalent cations includes, incertain embodiments, the water's temperature and pH, and in someinstances, the concentrations of additives and ionic species in thewater. Precipitation conditions may also include factors such as mixingrate, forms of agitation such as ultrasonics, and the presence of seedcrystals, catalysts, membranes, or substrates. In some embodiments,precipitation conditions include supersaturated conditions, temperature,pH, and/or concentration gradients, or cycling or changing any of theseparameters. The protocols employed to prepare carbonate-containingprecipitation material according to the invention may be batch orcontinuous protocols. It will be appreciated that precipitationconditions may be different to produce a given precipitation material ina continuous flow system compared to a batch system.

In certain embodiments, the methods further include contacting thevolume of water that is subjected to the mineral precipitationconditions with a source of CO₂. Contact of the water with the source ofCO₂ may occur before and/or during the time when the water is subjectedto CO₂ precipitation conditions. Accordingly, embodiments of theinvention include methods in which the volume of water may be contactedwith a source of CO₂ prior to subjecting the volume of saltwater tomineral precipitation conditions. Embodiments of the invention includemethods in which the volume of saltwater may be contacted with a sourceof CO₂ while the volume of saltwater is being subjected to carbonatecompound precipitation conditions. Embodiments of the invention includemethods in which the volume of water may be contacted with a source of aCO₂ both prior to subjecting the volume of saltwater to carbonatecompound precipitation conditions and while the volume of saltwater isbeing subjected to carbonate compound precipitation conditions. In someembodiments, the same water may be cycled more than once, wherein afirst cycle of precipitation removes primarily calcium carbonate andmagnesium carbonate minerals, and leaves remaining alkaline water towhich other alkaline earth ion sources may be added, that can have morecarbon dioxide cycled through it, precipitating more carbonatecompounds.

The source of CO₂ that may be contacted with the volume of saltwater inthese embodiments may be any convenient CO₂ source, and the contactprotocol may be any convenient protocol. Where the CO₂ is a gas, contactprotocols of interest include, but are not limited to: direct contactingprotocols, e.g., bubbling the gas through the volume of saltwater,concurrent contacting means, i.e., contact between unidirectionallyflowing gaseous and liquid phase streams, countercurrent means, i.e.,contact between oppositely flowing gaseous and liquid phase streams, andthe like. Thus, contact may be accomplished through use of infusers,bubblers, fluidic Venturi reactor, sparger, gas filter, spray, tray, orpacked column reactors, and the like, as may be convenient. Forexemplary system and methods for contacting the solution of divalentcations with the source of CO₂, see U.S. Provisional Patent ApplicationNos. 61/158,992, filed 10 Mar. 2009; 61/168,166, filed 9 Apr. 2009;61/170,086, filed 16 Apr. 2009; 61/178,475, filed 14 May 2009;61/228,210, filed 24 Jul. 2009; 61/230,042, filed 30 Jul. 2009; and61/239,429, filed 2 Sep. 2009, each of which is incorporated herein byreference.

The above protocol results in the production of a slurry of acarbonate/bicarbonate precipitation material (e.g., CO₂-sequesteringprecipitation material) and a mother liquor. Where desired, thecompositions made up of the precipitation material and the mother liquormay be stored for a period of time following precipitation and prior tofurther processing. For example, the composition may be stored for aperiod of time ranging from 1 to 1000 days or longer, such as 1 to 10days or longer, at a temperature ranging from 1 to 40° C., such as 20 to25° C.

The slurry components may then be separated. Embodiments may includetreatment of the mother liquor, where the mother liquor may or may notbe present in the same composition as the product. For example, wherethe mother liquor is to be returned to the ocean, the mother liquor maybe contacted with a gaseous source of CO₂ in a manner sufficient toincrease the concentration of carbonate ion present in the motherliquor. Contact may be conducted using any convenient protocol, such asthose described above. In certain embodiments, the mother liquor has analkaline pH, and contact with the CO₂ source may be carried out in amanner sufficient to reduce the pH to a range between 5 and 9, e.g., 6and 8.5, including 7.5 to 8.2. In certain embodiments, the treated brinemay be contacted with a source of CO₂, e.g., as described above, tosequester further CO₂. For example, where the mother liquor is to bereturned to the ocean, the mother liquor may be contacted with a gaseoussource of CO₂ in a manner sufficient to increase the concentration ofcarbonate ion present in the mother liquor. Contact may be conductedusing any convenient protocol, such as those described above. In certainembodiments, the mother liquor has an alkaline pH, and contact with theCO₂ source may be carried out in a manner sufficient to reduce the pH toa range between 5 and 9, e.g., 6 and 8.5, including 7.5 to 8.2.

The resultant mother liquor of the reaction may be disposed of using anyconvenient protocol. In certain embodiments, it may be sent to atailings pond for disposal. In certain embodiments, it may be disposedof in a naturally occurring body of water, e.g., ocean, sea, lake orriver. In certain embodiments, the mother liquor is returned to thesource of feed water for the methods of invention, e.g., an ocean orsea. Alternatively, the mother liquor may be further processed, e.g.,subjected to desalination protocols, as described further in U.S. patentapplication Ser. No. 12/163,205; the disclosure of which is incorporatedherein by reference.

In certain embodiments, following production of the precipitationmaterial (e.g., CO₂-sequestering component), the resultant material maybe separated from the mother liquor to produce separated precipitationmaterial (e.g., CO₂-sequestering product). Separation of theprecipitation material (e.g., CO₂-sequestering component) may beachieved using any convenient approach, including a mechanical approach,e.g., where bulk excess water is drained from the precipitationmaterial, e.g., either by gravity alone or with the addition of vacuum,mechanical pressing, by filtering the precipitation material from themother liquor to produce a filtrate, etc. Separation of bulk waterproduces, in certain embodiments, a wet, dewatered precipitationmaterial.

The resultant dewatered precipitation material may then be dried, asdesired, to produce a dried product. Drying may be achieved by airdrying the wet precipitation material. Where the wet precipitationmaterial is air dried, air drying may be at room or elevatedtemperature. In yet another embodiment, the wet precipitation materialmay be spray dried to dry the precipitation material, where the liquidcontaining the precipitation material is dried by feeding it through ahot gas (such as the gaseous waste stream from the power plant), e.g.,where the liquid feed is pumped through an atomizer into a main dryingchamber and a hot gas is passed as a co-current or counter-current tothe atomizer direction. Depending on the particular drying protocol ofthe system, the drying station may include a filtration element, freezedrying structure, spray drying structure, etc. Where desired, thedewatered precipitation material product may be washed before drying.The precipitation material may be washed with freshwater, e.g., toremove salts (such as NaCl) from the dewatered precipitation material.

In certain embodiments, the precipitation material may be refined (i.e.,processed) in some manner prior to subsequent use. Refinement mayinclude a variety of different protocols. In certain embodiments, theproduct may be subjected to mechanical refinement, e.g., grinding, inorder to obtain a product with desired physical properties, e.g.,particle size, etc.

In some embodiments, the product may be employed as a “supplementarycementitious material” (SCM). SCMs are those materials which, thoughthey may or may not be hydraulically cementitious in and of themselves,react to a degree with a hydraulic cement composition, such as Portlandcement, to produce a cured material. Examples of common SCMs for use inPortland cement compositions include fly ash and ground granulated blastfurnace slag.

In certain embodiments, the product may be utilized to produceaggregates. The resultant precipitation material may then prepared as anaggregate, with or without drying the powders. In certain embodimentswhere the drying process produces particles of the desired size, littleif any additional work may be required to produce the aggregate. In yetother embodiments, further processing of the precipitation material maybe performed in order to produce the desired aggregate. For example, asnoted above, the precipitation material may be combined with fresh waterin a manner sufficient to cause the precipitation material to form asolid product, where the metastable carbonate compounds present in theprecipitation material have converted to a form that is stable in freshwater. By controlling the water content of the wet material, theporosity, and eventual strength and density of the final aggregate maybe controlled. Typically a wet cake will be 40-60 volume % water. Fordenser aggregates, the wet cake will be <50% water, for less densecakes, the wet cake will be >50% water. After hardening, the resultantsolid product may then be mechanically processed, e.g., crushed orotherwise broken up and sorted to produce aggregate of the desiredcharacteristics, e.g., size, particular shape, etc. In these processesthe setting and mechanical processing steps may be performed in asubstantially continuous fashion or at separate times. In certainembodiments, large volumes of precipitation material may be stored inthe open environment where the precipitation material is exposed to theatmosphere. For the setting step, the precipitation material may beirrigated in a convenient fashion with fresh water, or allowed to berained on naturally or order to produce the set product. The set productmay then be mechanically processed as described above. Followingproduction of the precipitation material, the precipitation material maybe processed to produce the desired aggregate. In some embodiments, theprecipitation material may be left outdoors, where rainwater may be usedas the freshwater source, to cause the meteoric water stabilizationreaction to occur, hardening the precipitation material to formaggregate.

In an example of one embodiment of the invention, the precipitationmaterial may be mechanically spread in a uniform manner using a beltconveyor and highway grader onto a compacted earth surface to a depth ofinterest, e.g., up to twelve inches, such as 1 to 12 inches, including 6to 12 inches. The spread material may then be irrigated with fresh waterat a convenient rate, e.g., of one/half gallon of water per cubic footof precipitation material. The material may then be compacted usingmultiple passes with a steel roller, such as those used in compactingasphalt. The surface may be re-irrigated on a weekly basis until thematerial exhibits the desired chemical and mechanical properties, atwhich point the material may be mechanically processed into aggregate bycrushing.

In an example of an additional embodiment of the invention, thecarbonate compound precipitation material, once separated from themother liquor, may be washed with fresh water, then placed into a filterpress to produce a filter cake with 30-60% solids. This filter cake maythen be mechanically pressed in a mold, using any convenient means,e.g., a hydraulic press, at adequate pressures, e.g., ranging from 5 to1000 psi, such as 1 to 200 psi, to produce a formed solid, e.g., arectangular brick. These resultant solids may then be cured, e.g., byplacing outside and storing, by placing in a chamber within which theyare subjected to high levels of humidity and heat, etc. These resultantcured solids may then be used as building materials themselves orcrushed to produce aggregate. Such aggregates, methods for theirmanufacture and use are further described in co-pending U.S. PatentApplication No. 61/056,972, filed on May 29, 2008, the disclosure ofwhich is incorporated herein by reference.

FIG. 1 provides a schematic flow diagram of a process for producing acarbonate/bicarbonate (e.g., CO₂-sequestering component) according to anembodiment of the invention. In FIG. 1, divalent cations from source ofdivalent cations 110 is subjected to carbonate compound precipitationconditions at precipitation step 120. As reviewed above, saltwaterrefers to any of a number of different types of aqueous fluids otherthan freshwater, including brackish water, seawater and brine (includingman-made brines, e.g., geothermal plant wastewaters, desalination wastewaters, etc), as well as other salines having a salinity greater thanthat of freshwater. The saltwater source from which the carbonatecompound composition of the cements of the invention may be derived maybe a naturally occurring source, such as a sea, ocean, lake, swamp,estuary, lagoon, etc., or a man-made source.

In certain embodiments, the water may be obtained from the power plantthat is also providing the gaseous waste stream. For example, in watercooled power plants, such as seawater cooled power plants, water thathas been employed by the power plant may then be sent to theprecipitation system and employed as the water in the precipitationreaction. In certain of these embodiments, the water may be cooled priorto entering the precipitation reactor.

In the embodiment depicted in FIG. 1, a solution of divalent cationsfrom the source of divalent cations 110 is first charged with CO₂ toproduce CO₂-charged water, which CO₂ is then subjected to carbonatecompound precipitation conditions. As depicted in FIG. 1, aCO₂-containing gaseous stream 130 is contacted with the solution ofdivalent cations at precipitation step 120. The provided gaseous stream130 is contacted with a suitable divalent-cation containing solution atprecipitation step 120 to produce a CO₂-charged water. CO₂-charged wateris water that has been in contact with CO₂ gas, where CO₂ molecules havecombined with water molecules to produce, e.g., carbonic acid,bicarbonate and carbonate ion. Charging water in this step results in anincrease in the “CO₂ content” of the water, e.g., in the form ofcarbonic acid, bicarbonate and carbonate ion, and a concomitant decreasein the pCO₂ of the waste stream that is contacted with the water. TheCO₂-charged water may be acidic, having a pH of 6 or less, such as 5 orless and including 4 or less. In certain embodiments, the concentrationof CO₂ of the gas used to charge the water may be 10% or higher, 25% orhigher, including 50% or higher, such as 75% or even higher. Contactprotocols of interest include, but are not limited to: direct contactingprotocols, e.g., bubbling the gas through the volume of water,concurrent contacting means, i.e., contact between unidirectionallyflowing gaseous and liquid phase streams, countercurrent means, i.e.,contact between oppositely flowing gaseous and liquid phase streams, andthe like. Thus, contact may be accomplished through use of infusers,bubblers, fluidic Venturi reactor, sparger, gas filter, spray, tray, orpacked column reactors, and the like, as may be convenient.

At precipitation step 120, carbonate compounds, which may be amorphousor crystalline, are precipitated. Precipitation conditions of interestinclude those that change the physical environment of the water toproduce the desired precipitation material. For example, the temperatureof the water may be raised to an amount suitable for precipitation ofthe desired carbonate compound(s) to occur. In such embodiments, thetemperature of the water may be raised to a value from 5 to 70° C., suchas from 20 to 50° C. and including from 25 to 45° C. As such, while agiven set of precipitation conditions may have a temperature rangingfrom 0 to 100° C., the temperature may be raised in certain embodimentsto produce the desired precipitation material. In certain embodiments,the temperature may be raised using energy generated from low or zerocarbon dioxide emission sources, e.g., solar energy source, wind energysource, hydroelectric energy source, etc. While the pH of the water mayrange from 7 to 14 during a given precipitation process, in certainembodiments the pH may be raised to alkaline levels in order to drivethe precipitation of carbonate compound as desired. In certain of theseembodiments, the pH may be raised to a level that minimizes if noteliminates CO₂ gas generation production during precipitation. In theseembodiments, the pH may be raised to 10 or higher, such as 11 or higher.Where desired, the pH of the water may be raised using any convenientapproach. In certain embodiments, a pH-raising agent may be employed,where examples of such agents include oxides, hydroxides (e.g., sodiumhydroxide, potassium hydroxide, brucite), carbonates (e.g. sodiumcarbonate) and the like. The amount of pH-elevating agent that is addedto the saltwater source will depend on the particular nature of theagent and the volume of saltwater being modified, and will be sufficientto raise the pH of the saltwater source to the desired value.Alternatively, the pH of the saltwater source may be raised to thedesired level by electrolysis of the water.

CO₂ charging and carbonate compound precipitation may occur in acontinuous process or at separate steps. As such, charging andprecipitation may occur in the same reactor of a system, e.g., asillustrated in FIG. 1 at step 120, according to certain embodiments ofthe invention. In yet other embodiments of the invention, these twosteps may occur in separate reactors, such that the water is firstcharged with CO₂ in a charging reactor (i.e., a gas-liquid orgas-liquid-solid contactor) and the resultant CO₂-charged water is thensubjected to precipitation conditions in a separate reactor.

Following production of the carbonate-containing precipitation materialfrom the water, the resultant precipitation material (i.e., resultantCO₂-sequestering component) may be separated from some or all the motherliquor to produce separated precipitation material, as illustrated inFIG. 1 at step 140. Separation of the precipitation material may beachieved using any convenient approach, including a mechanical approach,e.g., where bulk excess water is drained from the precipitationmaterial, e.g., either by gravity alone or with the addition of vacuum,mechanical pressing, by filtering the precipitation material from themother liquor to produce a filtrate, etc. For exemplary system andmethods for bulk water removal that may be used in the invention, seeU.S. Provisional Patent Application Nos. 61/158,992, filed 10 Mar. 2009;61/168,166, filed 9 Apr. 2009; 61/170,086, filed 16 Apr. 2009;61/178,475, filed 14 May 2009; 61/228,210, filed 24 Jul. 2009;61/230,042, filed 30 Jul. 2009; and 61/239,429, filed 2 Sep. 2009, eachof which is incorporated herein by reference. Separation of bulk waterproduces a wet, dewatered precipitation material (i.e., dewateredCO₂-sequestering component of reduced-carbon footprint concretecompositions).

The resultant dewatered precipitation material may be used directly, orthe resultant dewatered precipitation material may be further dried. Insome embodiments, the resultant dewatered precipitation material may beused directly. Directly using the resultant dewatered precipitationmaterial may be convenient in applications that require some amount ofwater. In a non-limiting example, dewatered precipitation material maybe mixed with ordinary Portland cement, wherein the dewateredprecipitation material provides at least a portion of the water neededfor hydration and placement of the cement mixture. In some embodiments,the dewatered precipitation material may be more than 5% water, morethan 10% water, more than 20% water, more than 30% water, more than 50%water, more than 60% water, more than 70% water, more than 80% water,more than 90% water, or more than 95% water. In some embodiments, thedewatered precipitation material provides at least 5% of the water, atleast 10% of the water, at least 20% of the water, at least 30% of thewater, at least 40% of the water, at least 50% of the water, at least60% of the water, at least 70% of the water, at least 80% of the water,at least 90% of the water, or at least 95% of the water needed for theapplication that the dewatered precipitation material is being used. Insome embodiments, the dewatered precipitation material provides all ofthe water needed for the application that the dewatered precipitationmaterial is being used. For example, the dewatered precipitationmaterial may provide all of the water needed for hydration and placementof a cement mixture of dewatered precipitation material and ordinaryPortland cement. For instance, precipitation material may be dewateredsuch that the dewatered precipitation material comprises nearly 70%water, such as 66.5% water. The slurry of precipitation material maythen be mixed with ordinary Portland cement such that the resultantcement mixture comprises 80% ordinary Portland cement and 20%precipitation material, wherein the water to cement (i.e., ordinaryPortland cement and precipitation material) ratio is about 40%. Bycontrolling the amount of water that is removed from the precipitationmaterial, the carbon footprint of the material (e.g., reduced-carbonfootprint concrete) being made from the precipitation material is beingcontrolled as well, especially if the material requires water. With thisin mind, the small, neutral, or negative carbon footprint of any of theproduct materials described herein may be further reduced by removingonly as much water as needed from the precipitation material.

As described above, the resultant dewatered precipitation material mayalso be dried to produce a product, as illustrated at step 160 ofFIG. 1. Drying may be achieved by air-drying the filtrate. Where thefiltrate is air dried, air-drying may be at room or elevatedtemperature. Dewatered precipitation material may be air dried toproduce a precipitation material that may be less than 50% water, lessthan 40% water, less than 30% water, less than 20% water, less than 10%water, or less than 5% water. For example, dewatered precipitationmaterial may be air dried to produce a precipitation material that is30% or less water. Such precipitation material may be crushed with orwithout additional processing (e.g., high sheer mixing) and combinedwith other materials such as ordinary Portland cement to produce acement mixture comprising a portion of the water needed for hydrationand placement of the cement mixture. Drying may also be achieved byspray drying the precipitation material, where the liquid containing theprecipitation material is dried by feeding it through a hot gas (such asthe gaseous waste stream from the power plant), e.g., where the liquidfeed is pumped through an atomizer into a main drying chamber and a hotgas is passed as a co-current or counter-current to the atomizerdirection. Depending on the particular drying protocol of the system,the drying station may include a filtration element, freeze dryingstructure, spray drying structure, etc.

Where desired, the dewatered precipitation material from liquid-solidseparation may be washed before drying, as illustrated at optional step150 of FIG. 1. The precipitation material may be washed with freshwater,e.g., to remove salts (such as NaCl) from the dewatered precipitationmaterial. Used wash water may be disposed of as convenient, e.g., bydisposing of it in a tailings pond, etc.

At step 170, the dried precipitation material may be optionally refined,e.g., to provide for desired physical characteristics, such as particlesize, surface area, etc., or to add one or more components to theprecipitation material, such as admixtures, aggregate, supplementarycementitious materials, etc., to produce a final product 80.

FIGS. 4, 5, and 6 provide depictions of additional embodiments ofprocesses for preparing CO₂-sequestering products. In FIG. 6, the sourceof CO₂ is directly from power plant flue gas. The flue gas may bedissolved into seawater, stripping the gas of CO₂, SOx, and NOx toexhaust clean air. When dissolved, the CO₂ converts to carbonic acid andforms carbonates with divalent cations (e.g., Ca²⁺, Mg²⁺) in theseawater to create SCM and aggregates, while the NOx and SOx areneutralized and sequestered as well. A slurry containing carbonates(e.g., calcium and/or magnesium carbonate) may formed and spray dried tocreate the desired particle sizes. The process includes sophisticatedcontrols on sodium chloride, avoiding corrosive effects on reinforcementbar, and generates clean air and clean water that may be easier todesalinate due to reduced hardness (e.g., reduced concentrations ofcalcium and magnesium). Although magnesium is viewed as undesirable inconcrete, this form of MgCO₃ is more akin to CaCO₃, rather thanmagnesium hydroxide (Mg(OH)₂), which is typically avoided.

In certain embodiments, a system such as system 200 of FIG. 2 may beemployed to perform the above methods. System 200 of FIG. 2 includesCO₂-containing gas source 230 (e.g., flue gas from a coal-fired powerplant). This system also includes a conveyance structure such as a pipe,duct, or conduit, which directs the CO₂-containing gas to processor 220from CO₂-containing gas source 230. Also shown in FIG. 2 is divalentcation-containing solution source 210 (e.g., body of water, tank ofdivalent cation-containing solution, etc.). In some embodiments,divalent cation-containing solution source 210 includes a conveyancestructure such as a pipe, duct, or conduit, which directs the divalentcation-containing solution (e.g., alkaline earth metal ion-containingaqueous solution) to the processor (220). Where the divalentcation-containing solution source is seawater, the conveyance structureis in fluid communication with the source of seawater (e.g., the inputis a pipe line or feed from ocean water to a land-based system, or theinput is an inlet port in the hull of ship in an ocean-based system).

The aqueous solution of divalent cations provided to the processor or acomponent thereof (e.g. gas-liquid contactor, gas-liquid-solidcontactor; etc.) may be recirculated by a recirculation pump such thatabsorption of CO₂-containing gas (e.g., comprising CO₂, SOx, NOx, metalsand metal-containing compounds, particulate matter, etc.) is optimizedwithin a gas-liquid contactor or gas-liquid-solid contactor within theprocessor. With or without recirculation, processors of the invention ora component thereof (e.g. gas-liquid contactor, gas-liquid-solidcontactor; etc.) may effect at least 25%, 50%, 70%, or 90% dissolutionof the CO₂ in the CO₂-containing gas. Dissolution of other gases (e.g.,SOx) may be even greater, for example, at least 95%, 98%, or 99%.Additional parameters that provide optimal absorption of CO₂-containinggas include a specific surface area of 0.1 to 30, 1 to 20, 3 to 20, or 5to 20 cm⁻¹; a liquid side mass transfer coefficient (k_(L)) of 0.05 to2, 0.1 to 1, 0.1 to 0.5, or 0.1 to 0.3 cm/s; and a volumetric masstransfer coefficient (K_(L)a) of 0.01 to 10, 0.1 to 8, 0.3 to 6, or 0.6to 4.0 s⁻¹. In some embodiments, absorption of CO₂-containing gas by theaqueous solution of divalent cations causes precipitation of at least aportion of precipitation material in the gas-liquid contactor. In someembodiments, precipitation primarily occurs in a precipitator of theprocessor. The processor, while providing a structure for precipitationof precipitation material, may also provide a preliminary means forsettling (i.e., the processor may act as a settling tank). Theprocessor, whether providing for settling or not, may provide a slurryof precipitation material to a dewatering feed pump, which, in turn,provides the slurry of precipitation material to the liquid-solidseparator where the precipitation material and the precipitationreaction mixture are separated.

The processor 220 may further include any of a number of differentcomponents, including, but not limited to, temperature regulators (e.g.,configured to heat the precipitation reaction mixture to a desiredtemperature); chemical additive components (e.g., for introducingchemical proton-removing agents such as hydroxides, metal oxides, or flyash); electrochemical components (e.g., cathodes/anodes); components formechanical agitation and/or physical stirring mechanisms; and componentsfor recirculation of industrial plant flue gas through the precipitationplant. Processor 220 may also contain components configured formonitoring one or more parameters including, but not limited to,internal reactor pressure, pH, precipitation material particle size,metal-ion concentration, conductivity, alkalinity, and pCO₂. Processor220, in step with the entire precipitation plant, may operate as batchwise, semi-batch wise, or continuously.

Processor 220, further includes an output conveyance for slurrycomprising precipitation material or separated supernatant. In someembodiments, the output conveyance may be configured to transport theslurry or supernatant to a tailings pond for disposal or a naturallyoccurring body of water, e.g., ocean, sea, lake, or river. In otherembodiments, systems may be configured to allow for the slurry orsupernatant to be employed as a coolant for an industrial plant by aline running between the precipitation system and the industrial plant.In certain embodiments, the precipitation plant may be co-located with adesalination plant, such that output water from the precipitation plantis employed as input water for the desalination plant. The systems mayinclude a conveyance (i.e., duct) where the output water (e.g., slurryor supernatant) may be directly pumped into the desalination plant.

The system illustrated in FIG. 2 further includes a liquid-solidseparator 240 for separating precipitation material from precipitationreaction mixture The liquid-solid separator may achieve separation ofprecipitation material from precipitation reaction mixture by draining(e.g., gravitational sedimentation of the precipitation materialfollowed by draining), decanting, filtering (e.g., gravity filtration,vacuum filtration, filtration using forced air), centrifuging, pressing,or any combination thereof. At least one liquid-solid separator isoperably connected to the processor such that precipitation reactionmixture may flow from the processor to the liquid-solid separator. Anyof a number of different liquid-solid separators may be used incombination, in any arrangement (e.g., parallel, series, or combinationsthereof), and the precipitation reaction mixture may flow directly tothe liquid-solid separator, or the precipitation reaction mixture may bepre-treated.

System 200 also includes a washer (250) where bulk dewateredprecipitation material from liquid-solid separator 240 is washed (e.g.,to remove salts and other solutes from the precipitation material),prior to drying at the drying station (e.g., dryer 260).

The system may further include a dryer 260 for drying the precipitationmaterial comprising carbonates (e.g., calcium carbonate, magnesiumcarbonate), bicarbonates, or a combination thereof produced in theprocessor. Depending on the particular system, the dryer may include afiltration element, freeze-drying structure, spray-drying structure, orthe like. The system may include a conveyer (e.g., duct) from theindustrial plant that is connected to the dryer so that a CO₂-containinggas (i.e., industrial plant flue gas) may be contacted directly with thewet precipitation material in the drying stage.

The dried precipitation material may undergo further processing (e.g.,grinding, milling) in refining station 270 in order to obtain desiredphysical properties. One or more components may be added to theprecipitation material during refining if the precipitation material isto be used as a building material.

The system further includes outlet conveyers (e.g., conveyer belt,slurry pump) configured for removal of precipitation material from oneor more of the following: the processor, dryer, washer, or from therefining station. As described above, precipitation material may bedisposed of in a number of different ways. The precipitation materialmay be transported to a long-term storage site in empty conveyancevehicles (e.g., barges, train cars, trucks, etc.) that may include bothabove ground and underground storage facilities. In other embodiments,the precipitation material may be disposed of in an underwater location.Any convenient conveyance structure for transporting the precipitationmaterial to the site of disposal may be employed. In certainembodiments, a pipeline or analogous slurry conveyance structure may beemployed, wherein these structures may include units for active pumping,gravitational mediated flow, and the like.

A person having ordinary skill in the art will appreciate that flowrates, mass transfer, and heat transfer may vary and may be optimizedfor systems and methods described herein, and that parasitic load on apower plant may be reduced while carbon sequestration is maximized.

Settable Compositions

Additional aspects of the invention are settable compositions thatinclude reduced-carbon footprint concrete compositions of the inventioncombined with a water. Settable compositions of the invention may beproduced by combining the concrete composition and water, either at thesame time or by pre-combining a cement with aggregate, and thencombining the resultant dry components with water.

The liquid phase, e.g., aqueous fluid, with which the dry component maybe combined to produce the settable composition, e.g., concrete, mayvary, from pure water to water that includes one or more solutes,additives, co-solvents, etc., as desired. The ratio of dry component toliquid phase that is combined in preparing the settable composition mayvary, and in certain embodiments ranges from 2:10 to 7:10, such as 3:10to 6:10 and including 4:10 to 6:10.

Current cement standards such as ASTM C150 allow for the substitution ofground limestone for a portion of the clinker in making Portland cement.In the case of ASTM C150 the maximum allowable percentage is 5%. In someEuropean standards there is allowance of higher percentages, often 10%but at times as high as 30%, of limestone as clinker replacement inmaking Portland cement. In these cases the limestone may be groundseparately and blended with the Portland cement, but limestone aggregatemay also be added to the clinker at the ball-milling stage andinterground with the clinker and a small amount of gypsum to producePortland cement.

The use of a calcium carbonate additive from a carbon sequestrationprecipitation reaction rather than natural mined limestone has severaladvantages for the cement producer. Assuming a 5% replacement of clinkerwith the precipitation material, the carbon footprint of the resultantcement may be reduced 7.2%, whereas in using ground limestone the carbonfootprint may be only reduced 5% or less. Given the pressure on carbonfootprint reduction which the Portland cement industry faces, theadditional 2.2% further reduction in carbon footprint versus using minedlimestone has considerable value.

An additional benefit of the use of a precipitated calcium carbonate asclinker replacement is that it is generally more pure than minedlimestone. In many instances, impurities in the limestone limit the useof that limestone to less than the full allowed amount, due toimpurities which reduce the properties of the resultant Portland cement.In certain Portland cement plants, ability to use local mined limestoneis limited to perhaps 2.0%. The utilization of a carbon-sequesteringprecipitated calcium carbonate at 5% would result in an improvement incarbon footprint reduction of 5.2%, from 2.0% to 7.2%.

Reduction in carbon footprint of Portland cement by usingcarbon-sequestering precipitated calcium carbonate has the furtheradvantage of potentially producing additional revenue via carboncredits. Because the material added, even if it is mined limestone,reduces the amount of clinker used, there is potential for obtainingcarbon credits for emissions reduction from the cement facility. Thesequestered CO₂ in the precipitation material may be utilized toincrease the amount and value of the carbon credits available forclinker reduction.

Utility

The subject concretes and settable compositions that include the same,find use in a variety of different applications, particularly asbuilding or construction materials. Specific structures in which thesettable compositions of the invention find use include, but are notlimited to: pavements, architectural structures, e.g., buildings,foundations, motorways/roads, overpasses, parking structures,brick/block walls and footings for gates, fences and poles, bridges,foundations, levees, dams. Mortars of the invention find use in bindingconstruction blocks, e.g., bricks, together and filling gaps betweenconstruction blocks. Mortars can also be used to fix existing structure,e.g., to replace sections where the original mortar has becomecompromised or eroded, among other uses.

Embodiments of the invention find use in reducing the amount of CO₂ thatis generated in producing buildings and then operating buildings.Specifically, the methods of the invention can reduce CO₂ generation inproduction of building materials, e.g., concrete. In addition, themethods can reduce CO₂ emission in power generation, which reduces CO₂emissions connected with operating a building during its life.

The subject methods and systems find use in CO₂ sequestration,particularly via sequestration in the built environment. SequesteringCO₂ comprises removal or segregation of CO₂ from the gaseous stream,such as a gaseous waste stream, and fixating it into a stablenon-gaseous form so that the CO₂ cannot escape into the atmosphere. CO₂sequestration comprises the placement of CO₂ into a storage stable form,e.g., a component of the built environment, such as a building, road,dam, levee, foundation, etc. As such, sequestering of CO₂ according tomethods of the invention results in prevention of CO₂ gas from enteringthe atmosphere and long-term storage of CO₂ in a manner that CO₂ doesnot become part of the atmosphere. By storage stable form is meant aform of matter that may be stored above ground or underwater underexposed conditions (i.e., open to the atmosphere, underwaterenvironment, etc.) without significant, if any, degradation for extendeddurations, e.g., 1 year or longer, 5 years or longer, 10 years orlonger, 25 years or longer, 50 years or longer, 100 years or longer, 250years or longer, 1000 years or longer, 10,000 years or longer, 1,000,000years or longer, or even 100,000,000 years or longer. As the storagestable form undergoes little if any degradation while stored, the amountof degradation if any as measured in terms of CO₂ gas release from theproduct will not exceed 5%/year, and in certain embodiments will notexceed 1%/year. The above-ground storage stable forms may be storagestable under a variety of different environment conditions, e.g., fromtemperatures ranging from −100° C. to 600° C., humidity ranging from 0to 100%, where the conditions may be calm, windy, turbulent or stormy.The below water storage stable forms are similarly stable to withrespect to underwater environment conditions. Embodiments of the methodsmay be used to capture all the waste CO₂ of industrial processes, e.g.,power generation, cement production, chemical production, paper andsteel mills, etc.

The following examples are put forth so as to provide those of ordinaryskill in the art with a complete disclosure and description of how tomake and use the invention, and are not intended to limit the scope ofwhat the inventors regard as their invention nor are they intended torepresent that the experiments below are all or the only experimentsperformed. Efforts have been made to ensure accuracy with respect tonumbers used (e.g. amounts, temperature, etc.) but some experimentalerrors and deviations should be accounted for.

All examples and conditional language recited herein are principallyintended to aid the reader in understanding the principles of theinvention and the concepts contributed by the inventors to furtheringthe art, and are to be construed as being without limitation to suchspecifically recited examples and conditions. Moreover, all statementsherein reciting principles, aspects, and embodiments of the invention aswell as specific examples thereof, are intended to encompass bothstructural and functional equivalents thereof. Additionally, it isintended that such equivalents include both currently known equivalentsand equivalents developed in the future, i.e., any elements developedthat perform the same function, regardless of structure. The scope ofthe invention, therefore, is not intended to be limited to the exemplaryembodiments shown and described herein as such embodiments are providedby way of example only. Indeed, numerous variations, changes, andsubstitutions may now occur to those skilled in the art withoutdeparting from the invention. It is intended that the following claimsdefine the scope of the invention and that methods and structures withinthe scope of these claims and their equivalents be covered thereby.

EXAMPLES I. Components of Reduced-Carbon Footprint Concrete Compositions

A. Supplementary Cementitious Mineral Admixture (SCMA)

Supplementary cementitious mineral admixture (SCMA) is a partial or fullreplacement for traditional SCMs that may be blended with Portlandcement to significantly reduce the carbon footprint of concrete, whileincreasing the quality, strength, and durability of concrete. The SCMAis a reactive admixture that can replace a high volume of cement or flyash with increased durability without issues such as early strengthloss. The SCMA may be prepared as described in U.S. patent applicationSer. No. 12/126,776, as well as in U.S. Provisional Patent ApplicationNos. 61/088,347 and 61/101,626; each of which are incorporated herein byreference.

i. FTIR

The FTIR uses a laser to excite and measure bond vibrations inmaterials. Using this method, we can indicate which compounds arepresent in the materials. An unhydrated and hydrated comparison, at 7days, is shown in FIG. 7, between ordinary Portland cement paste (OPC)and a blended paste with 20% SCMA and 80% OPC. Though varied, the SCMAmay be the basis and building block for many products, and demonstratesthe basic chemical composition of all the products. In the above graph,the large band centered at 1450 cm⁻¹ indicates the large presence ofcarbonate in the SCMA. The peaks at 3694 cm⁻¹ and 2513 cm⁻¹ areindicative of the hydration of the SCMA. For the Hydrated Blended SCMA,we see the peak at 858 cm⁻¹ diminish with the peak at 872 cm⁻¹ becomingsharper, and the slope at 712 cm⁻¹ also sharpen. These mode locationsare consistent with the formation of Calcite. The 2342 cm⁻¹ peak notedabove is no longer present in the cement blend, which would be expectedupon re-hydration of the product. The peak at 3694 cm⁻¹ corresponding tothe OH stretching vibrations for Mg(OH)₂ is present, however Ca(OH)₂formation (peak at 3644 cm⁻¹) appears to be inhibited compared tohydration in OPC. For the Hydrated OPC, it too has the signature CO₃ ⁻²modes observable at 1481 cm⁻¹ and 1426 cm⁻¹ due to carbonation of thecement. Ca(OH)₂ has a large peak at 3644 cm⁻¹ that corresponds to the OHstretching vibrations as well.

ii. XRD

The XRD scatters X-ray beams at different angels to measure thereflection off a sample. The reflections return a fingerprint to allowidentification of a specific compound. From the XRD (See FIG. 8 and FIG.9), a number of observations can be made for the hydrated OPC andBlended SCMA:

-   -   Ettringite and portlandite are present in both the OPC and        blended SCMA.    -   The presence of calcite is shown in the SCMA, while the amount        of portlandite formed is significantly reduced by 20%.    -   After 7 days, the SCMA shows little or no sign of halite (NaCl),        or brucite, meeting ACI 318 standards for sodium chloride        control.    -   The SCMA shows evidence of depletion of Mg in the calcite.    -   The calcium silicate phases seem to be consumed faster in the        SCMA as well.

iii. SEM Images

SEM images (FIG. 10) show that both the Hydrated OPC and Blended SCMApastes exhibit similar morphologies with acicular ettringite and C—S—Hformation on the surface of the cement particles.

iv. X-Ray Fluorescence (XRF)

TABLE 1 XRF elemental analysis of an SCM of the invention. Oxide CaOSiO₂ Al₂O₃ Fe₂O₃ SO₃ Na₂O MgO Cl K₂O Content (weight %) 8.96 1.76 0.630.265 0.17 2.56 31.17 1.15 0.12 Elemental (weight %) 6.404 0.823 0.3340.185 0.068 11.37 18.79 1.15 0.100

v. Particle Size Analysis (PSA)

Particle size analysis of SCM of the invention indicates a medianparticle size of 10.86361 microns and a mean particle size of 11.26930microns.

vi. SCMA is Reactive

As demonstrated in FIG. 11, SCMA is reactive.

vii. SCM Morphologies

FIG. 12 provides SCM morphologies.

B. Carbon Reducing Admixture (CRA)

CRA is both a mineral admixture and fine aggregate with particle sizescomparable to sand. CRA sequesters CO₂ in concrete and gives designersthe potential to create carbon neutral or carbon negative concrete byreplacing a portion or all of the fine aggregates in a mix design,without any cement replacement. CRA is produced according to methodsdescribed in U.S. Provisional Patent Application No. 61/056,972; thedisclosure of which is incorporated herein by reference.

C. Coarse Aggregate (AGG).

Coarse aggregate (AGG) may replace a portion or all of the common coarseaggregate in a mix. AGG allows designers to create carbon neutral orcarbon negative concrete without replacing any cement, and maintainingthe strength of concrete. AGG CRA is produced according to methodsdescribed in U.S. Provisional Application No. 61/056,972; the disclosureof which is incorporated herein by reference.

D. Precipitation Material from Seawater

Seawater (900 gallons) was agitated and acidified by bubbling a 55 scfm,10% carbon dioxide (balance air) gas stream through gas diffuserslocated at the bottom of a 1,000-gallon, covered plastic tank. The pHwas monitored and dropped from approximately pH 8 to pH 5.5-6, at whichpoint the gas diffusion was stopped. Magnesium hydroxide (1 g/L) from anindustrial tailings pond that includes some calcite and silica was addedto the acidified, agitated sea water; the pH rose to approximately pH 8.Gas diffusion re-started until the pH dropped to pH 7, after which thegas flow was arrested.

A total of 22 kg of magnesium hydroxide was added as a 10% slurry to theacidic sea water in incremental doses in the following repeated manner:magnesium hydroxide slurry was added to agitated sea water until the pHincreased to pH 8. The 10% carbon dioxide gas delivery was re-starteduntil the pH of the agitated sea water returned to pH 7. The gasdelivery was arrested, and slurry added until the pH returned to pH 8.After 22 kg of magnesium hydroxide was consumed, the pH of the agitatedsea water was reduced to pH 7 by diffusion with 10% carbon dioxide gas,after which gas delivery was stopped. Approximately 43 kg of 50% (w/w)NaOH (aq) was added to the agitated sea water until the pH of the seawater reached pH 10.15. The resultant precipitation material was gravityseparated then vacuum filtered from the supernatant solution. The filtercake was oven-dried at 110° C., then ball milled.

Precipitation Material Characterization

X-ray fluorescence (XRF) data (Table 2) indicates that the precipitationmaterial is mostly composed of magnesium and calcium carbonates.

TABLE 2 XRF elemental analysis of precipitation material. Na Mg Al Si SCl K Ca Fe Weight % 1.86 19.48 0.28 0.71 0.07 1.36 0.13 8.10 0.20

TABLE 3 Percent CO₂ content (coulometry). % CO₂ Weight % 49.63

X-ray diffraction (XRD) and thermogravimetric analysis (TGA/DTG) of theprecipitation material indicate the presence of hydromagnesite andaragonite (CaCO₃) as the major phases, and halite (NaCl) as a minorcomponent. The XRD of the precipitation material was compared againststandards for hydromagnesite, aragonite, and hydromagnesite. The TGA/DTGindicated inflection points/peaks at 257° C. and 412° C. indicatinghydromagnesite, and the TGA/DTG indicated an inflection point/peak at707° C. indicating aragonite. The results were also confirmed byinfrared spectroscopy (IR), which was used to generate a composite plotfor each of aragonite, hydromagnesite, and the precipitation material.Such precipitation material is useful in production of reduced-carbonfootprint concrete compositions of the invention.

E. Precipitation Material from Seawater

Seawater (900 gallons) was agitated and acidified by bubbling a 55 scfm10% carbon dioxide (balance air) gas stream through gas diffuserslocated at the bottom of a 1,000-gallon, covered plastic tank. The pHwas monitored and dropped from approximately pH 8 to pH 5.5-6, at whichpoint the gas diffusion was stopped. Magnesium hydroxide (1 g/L) wasadded to the acidified, agitated sea water; the pH rose to approximatelypH 8. Gas diffusion was re-started until the pH dropped to pH 7, afterwhich the gas flow was arrested. A total of 30 kg of 50% (w/w) NaOH (aq)was then added to the agitated sea water in incremental doses in thefollowing repeated manner: NaOH was added to agitated sea water untilthe pH increased to pH 8. The 10% carbon dioxide gas delivery wasre-started until the pH of the agitated sea water returned to pH 7. Thegas delivery was arrested, and NaOH added until the pH returned to pH 8.After 30 kg of 50% (w/w) NaOH (aq) was consumed, the pH of the agitatedsea water was reduced to pH 7 by diffusion with 10% carbon dioxide gas,after which gas delivery was stopped. Approximately 37 kg of 50% (w/w)NaOH (aq) was added to the agitated sea water until the pH of the seawater reached pH 10.15. The resultant precipitation material was gravityseparated then vacuum filtered from the supernatant solution. The filtercake was re-slurried in fresh water, spray-dried, then ball milled.

Precipitation Material Characterization

X-ray fluorescence (XRF) data (Table 4) indicates that the precipitationmaterial is mostly composed of magnesium and calcium carbonates.

TABLE 4 XRF elemental analysis of precipitation material Na Mg Al Si SCl K Ca Fe Weight % 7.13 13.84 0.10 0.11 0.17 4.75 0.17 5.63 0.03

TABLE 5 Percent CO2 content (Coulometry) % CO₂ Weight % 53.60

X-ray diffraction (XRD) and thermogravimetric analysis (TGA/DTG) of theprecipitation material indicates the presence of nesquehonite(MgCO₃.3H₂O) and aragonite (CaCO₃) as the major phases, and halite(NaCl) as a minor component. The XRD of the precipitation material wascompared against standards for nesquehonite and aragonite. The TGA/DTGindicated inflection points/peaks at 132° C., 364° C., 393° C., and 433°C. indicating nesquehonite, and the TGA/DTG indicated an inflectionpoint/peak at 697° C. indicating aragonite. The results were alsoconfirmed by infrared spectroscopy (IR), which was used to generate acomposite plot for each of nesquehonite, aragonite, and theprecipitation material. Such precipitation material is useful inproduction of reduced-carbon footprint concrete compositions of theinvention.

F. Precipitation Material from Seawater

Seawater (76,000 gallons) was mixed in a 200,000-gallon open vessel bypumping its contents through two lines with two pumps, which returnedthe contents into the tank with an upward, circular trajectory. Carbondioxide gas (100%) was diffused into the seawater via diffusers locatedin the bottom of the tank to reduce the pH to about pH 5.5.Approximately 800 kg of magnesium hydroxide from a tailings pond,containing some calcite and silica, was slurried with seawater andinjected into the open vessel through a recirculation device based onthe operating premise of a pool sand-filter. After addition of themagnesium hydroxide, the 100% carbon dioxide gas delivery was arrested.Caustic (50% (w/w) NaOH (aq)) was then added through a recirculationline until the pH of the slurry was pH 9.5. The slurry was thentransferred to a settling pond where the supernatant was decanted andthe gravity-settled solids collected for spray drying. The slurry wasspray-dried and collected from the main chamber of the spray dryer.

Precipitation Material Characterization

X-ray fluorescence (XRF) data (not shown) indicates that theprecipitation material is mostly composed of magnesium and calciumcarbonates

TABLE 6 Percent CO2 content (Coulometry) % CO2 Weight % 33.06

X-ray diffraction (XRD) and thermogravimetric analysis (TGA/DTG) of theprecipitation material indicates the presence of nesquehonite(MgCO₃.3H₂O) and monohydrocalcite (CaCO₃.H₂O) as the major phases, andaragonite (CaCO₃) and halite (NaCl) as a minor components. The XRD ofthe precipitation material was compared against standards fornesquehonite, aragonite, and monohydrocalcite. The TGA/DTG indicatedinflection points/peaks at 136° C., 187° C., and 421° C. indicatingnesquehonite, and the TGA/DTG indicated an inflection point/peak at 771°C. indicating aragonite and monohydrocalcite. The results were alsoconfirmed by infrared spectroscopy (IR), which was used to generate acomposite plot for each of nesquehonite, aragonite, monohydrocalcite,and the precipitation material. Such precipitation material is useful inproduction of reduced-carbon footprint concrete compositions of theinvention.

II. Carbon Footprint Comparisons

Below are mix designs with corresponding carbon footprint reductionsexpected from using products of the invention. The carbon footprint ofconcrete is determined by multiplying the pounds per cubic yard of eachconstituent by its per pound carbon footprint, summing these values, andadding 10.560 kg/yd³ (the carbon footprint of transporting one yard ofconcrete 20 miles on average).

Transportation Footprint:

-   -   The European Commission has released figures of 160 g CO₂/tonne        of material/km for transportation by truck (for aggregate,        cement, and concrete). The Carbon footprint of cement shipped by        sea from Asia to California has been estimated to be 0.150 lb        CO₂ per pound of ocean-freighted material.    -   Assuming an average distance of 50 miles for hauling aggregate,        and a production carbon footprint of 0.03 lbs CO₂/lb aggregate,        the average carbon footprint of aggregate is approximately 0.043        lbs CO₂/lb aggregate.    -   Fly ash and slag rail costs from across the nation have been        estimated to be only 0.020 lbs per lbs of fly ash. Assuming an        average of 100 miles of trucking from the fly ash or slag, the        carbon footprint of conventional SCMs are approximately 0.045        lbs CO₂/lb fly ash or slag.

Production Footprint:

-   -   Assuming an average CO₂ release from Portland cement production        of 0.86 tonnes CO₂/tonne cement (as reported for California        Cement Climate Action Team), each pound of Portland cement has a        production carbon footprint of 0.86 pounds. Assuming an average        transportation distance of 100 miles, the transportation        footprint for each pound of Portland cement would be 0.016        pounds, for a total carbon footprint of 0.876 pounds CO₂ per        pound of Portland cement.

Carbon Reductions:

-   -   Materials such as SCMA, CRA, and AGG have a sequestered CO₂        content of roughly 50%, which is −0.500 pounds of CO₂ per pound        of material. Production and transportation carbon footprint        (assuming trucking distance of 100 miles on average) is        approximately 0.050 pounds of CO₂ per pound of material. Leaving        a total carbon footprint of −0.450 lbs CO₂ per pound of        material.

A. 100% OPC Mix

TABLE 7 Concrete composition having a carbon footprint of 630.18 lbsCO₂/yd³ concrete. lbs CO₂/lb lbs ingredient/yd³ Ingredient ingredientconcrete lbs CO₂/yd³ concrete Portland Cement 0.876 564 494.06 Water0.01 282 2.82 Fly Ash 0.045 0 0 SCMA (0.450) 0 0 Fine Aggregate 0.0431,300 55.90 CRA (0.450) 0 0 Coarse Aggregate 0.043 1,800 77.40 AGG(0.450) 0 0 TOTALS 3,946 630.18

This example of a typical 6-sack concrete mix has a carbon footprint of630 pounds per cubic yard. To mitigate this carbon emission biologicallywould require growing a one-foot diameter tree 27 feet tall. Each 10yard load equates to growing a grove of ten of these trees!

B. High Fly Ash (50%) Mix

TABLE 8 Concrete composition having a carbon footprint of 395.84 lbsCO₂/yd³ concrete. lbs CO₂/lb lbs ingredient/yd³ Ingredient ingredientconcrete lbs CO₂/yd³ concrete Portland Cement 0.876 282 247.03 Water0.01 282 2.82 Fly Ash 0.045 282 12.69 SCMA (0.450) 0 0 Fine Aggregate0.043 1,300 55.90 CRA (0.450) 0 0 Coarse Aggregate 0.043 1,800 77.40 AGG(0.450) 0 0 TOTALS 3,946 395.84

This example of a typical 6-sack concrete mix with 50% fly ashreplacement has a carbon footprint of 395 pounds per cubic yard. This isa reduction in carbon footprint of 37% from a straight 6-sack Portlandcement mixture.

C. Reduced Carbon Mix with Improved Working Properties

TABLE 9 Concrete composition having a carbon footprint of 386.44 lbsCO₂/yd³ concrete. lbs CO₂/lb lbs ingredient/yd³ Ingredient ingredientconcrete lbs CO₂/yd³ concrete Portland Cement 0.876 338 296.09 Water0.01 282 2.82 Fly Ash 0.045 113 5.08 SCMA (0.450) 113 (50.85) FineAggregate 0.043 1,300 55.90 CRA (0.450) 0 0 Coarse Aggregate 0.043 1,80077.40 AGG (0.450) 0 0 TOTALS 3,946 386.44

This example of a 6-sack concrete mix with 20% SCMA, 20% fly ash and 60%OPC has a carbon footprint of 386 pounds per cubic yard −2% lower carbonfootprint than a 50% OPC/50% fly ash mix. This mix achieves a lowercarbon footprint without the set-time and early strength gain issues of50% fly ash mixes, as illustrated in FIG. 3.

D. Carbon Neutral Mix with 6 Sacks of OPC

TABLE 10 Concrete composition having a carbon footprint of 494.06 lbsCO₂/yd³ concrete. lbs CO₂/lb lbs ingredient/yd³ Ingredient ingredientconcrete lbs CO₂/yd³ concrete Portland Cement 0.876 564 494.06 Water0.01 282 2.82 Fly Ash 0.045 0 0 SCMA (0.450) 0 0 Fine Aggregate 0.0431,300 55.90 CRA (0.450) 1,400 (630.00) Coarse Aggregate 0.043 1,70073.10 AGG (0.450) 0 0 TOTALS 3,946 (4.12)

This example of a carbon neutral 6-sack concrete mix uses CRA to replacea portion of the fine aggregate.

E. Carbon Neutral Mix with High OPC Replacement & Improved WorkingProperties

TABLE 11 Concrete composition having a carbon footprint of −3.96 lbsCO₂/yd³ concrete. lbs CO₂/lb lbs ingredient/yd³ Ingredient ingredientconcrete lbs CO₂/yd³ concrete Portland Cement 0.876 338 296.09 Water0.01 282 2.82 Fly Ash 0.045 113 5.08 SCMA (0.450) 113 (50.85) FineAggregate 0.043 600 25.50 CRA (0.450) 800 (360) Coarse Aggregate 0.0431,800 77.40 AGG (0.450) 0 0 TOTALS 3,946 (3.96)

This example of a carbon-neutral 6-sack concrete mix uses CRA to replacea portion of the fine aggregate along with the use of SCMA and fly ashwith each at a 20% replacement level.

Additional mixes of interest include:

TABLE 12 Concrete composition having a carbon footprint of 293 lbsCO₂/yd³ concrete. lb CO₂/lb lb ingredient/yd³ Ingredient ingredientconcrete lb CO₂/yd³ concrete Portland Cement 0.876 338 296.1 Water 0.01271 2.7 Fine Aggregate 0.013 1,250 16.3 Coarse Aggregate 0.013 1,80023.4 Fly Ash 0.045 113 5.1 CM-SCM (0.450) 113 (50.9) Fine-SA 0 0 0Coarse-SA 0 0 0 TOTALS 3,885 293

TABLE 13 Concrete composition having a carbon footprint of 386.7 lbsCO₂/yd³ concrete lb CO₂/lb lb ingredient/yd³ Ingredient ingredientconcrete lb CO₂/yd³ concrete. Portland Cement 0.876 451 395.1 Water 0.01282 2.8 Fine Aggregate 0.013 1250 16.3 Coarse Aggregate 0.013 1,800 23.4Fly Ash 0 0 0 CM-SCM (0.450) 113 (50.9) Fine-SA 0 0 0 Coarse-SA 0 0 0TOTALS 3,896 386.7

TABLE 14 Concrete composition having a carbon footprint of −0.9 lbsCO₂/yd³ concrete. lb CO₂/lb lb ingredient/yd³ Ingredient ingredientconcrete lb CO₂/yd³ concrete Portland Cement 0.876 338 296.1 Water 0.01271 2.7 Fine Aggregate 0.013 616 8.0 Coarse Aggregate 0.013 1,800 23.4Fly Ash 0.045 113 5.1 CM-SCM (0.450) 113 (50.9) Fine-SA (0.450) 634(285.3) Coarse-SA (0.450) 0 0 TOTALS 3,885 (0.9)

TABLE 15 Concrete composition having a carbon footprint of −0.8 lbsCO₂/yd³ concrete. lb CO₂/lb lb ingredient/yd³ Ingredient ingredientconcrete lb CO₂/yd³ concrete Portland Cement 0.876 564 494.1 Water 0.01282 2.8 Fine Aggregate 0.013 138 1.8 Coarse Aggregate 0.013 1,800 23.4Fly Ash 0.045 0 0 CM-SCM (0.450) 0 0 Fine-SA (0.450) 1,162 (522.9)Coarse-SA (0.450) 0 0 TOTALS 3,946 (0.8)

F. High Carbon Capturing Mixes

TABLE 16 Concrete composition having a carbon footprint of −1,168.86 lbsCO₂/yd³ concrete. lbs CO₂/lb lbs ingredient/yd³ Ingredient ingredientconcrete lbs CO₂/yd³ concrete Portland Cement 0.876 338 269.09 Water0.01 282 2.82 Fly Ash 0.045 113 5.08 SCMA (0.450) 113 (50.85) FineAggregate 0.043 0 0 CRA (0.450) 1,300 (585.00) Coarse Aggregate 0.043 00 AGG (0.450) 1,800 (810.00) TOTALS 3,946 (1,168.86)

This carbon-sequestering concrete illustrates the potential forhigh-carbon capturing concrete by using materials of the invention as areplacement for both coarse and fine aggregate as well as using SCMA andfly ash each at a 20% replacement level. Each 10-yard load of this mixis the carbon equivalent of growing 19 trees 1-foot in diameter and 27feet tall!

Additional High Carbon Capturing Formulations are provided below:

TABLE 17 Concrete composition having a carbon footprint of −1,119.47 lbsCO₂/yd³ concrete. lbs CO₂/lb lbs ingredient/yd Ingredient ingredientconcrete lbs CO₂/yd concrete Portland Cement 0.876 338 269.09 Water 0.01271 2.71 Fly Ash 0.045 113 5.09 SCMA (0.450) 113 (50.85) Fine Aggregate0.043 0 0 CRA (0.450) 1,250 (562.50) Coarse Aggregate 0.043 0 0 AGG(0.450) 1,800 (810.00) TOTALS 3,885 (1,119.47)

TABLE 18 Concrete composition having a carbon footprint of −1,146 lbsCO₂/yd³ concrete. lb CO₂/lb lb ingredient/yd³ Ingredient ingredientconcrete lb CO₂/yd³ concrete Portland Cement 0.876 338 269.1 Water 0.01271 2.7 Fine Aggregate 0.013 0 0 Coarse Aggregate 0.013 0 0 Fly Ash0.045 113 5.1 CM-SCM (0.450) 113 (50.9) Fine-SA (0.450) 1,250 (562.5)Coarse-SA (0.450) 1,800 (810.0) TOTALS 3,885 (1,146)

TABLE 19 Concrete composition having a carbon footprint of 1,145 lbsCO₂/yd³ concrete. lbs ingredient/yd lbs CO₂/lb Ingredient ingredientingredient lbs CO₂/yd concrete Portland Cement 338 0.88 270 Water 2820.01 3 Fine Aggregate 0 0.04 0 Coarse Aggregate 0 0.04 0 Fly Ash 1130.045 5 SCM 113 (0.45) (51) CRA 1,250 (0.45) (563) AGG 1,800 (0.45)(810) TOTALS 3,885 (1,145)

Although the foregoing invention has been described in some detail byway of illustration and example for purposes of clarity ofunderstanding, it is readily apparent to those of ordinary skill in theart in light of the teachings of this invention that certain changes andmodifications may be made thereto without departing from the spirit orscope of the appended claims.

Accordingly, the preceding merely illustrates the principles of theinvention. It will be appreciated that those skilled in the art will beable to devise various arrangements which, although not explicitlydescribed or shown herein, embody the principles of the invention andare included within its spirit and scope. Furthermore, all examples andconditional language recited herein are principally intended to aid thereader in understanding the principles of the invention and the conceptscontributed by the inventors to furthering the art, and are to beconstrued as being without limitation to such specifically recitedexamples and conditions. Moreover, all statements herein recitingprinciples, aspects, and embodiments of the invention as well asspecific examples thereof, are intended to encompass both structural andfunctional equivalents thereof. Additionally, it is intended that suchequivalents include both currently known equivalents and equivalentsdeveloped in the future, i.e., any elements developed that perform thesame function, regardless of structure. The scope of the presentinvention, therefore, is not intended to be limited to the exemplaryembodiments shown and described herein. Rather, the scope and spirit ofpresent invention is embodied by the appended claims.

1.-30. (canceled)
 31. A method comprising: a) precipitating synthetic carbonates and/or bicarbonates from a solution comprising divalent cations and dissolved CO₂ from an industrial waste gas comprising CO₂; b) producing one or more concrete components selected from the group consisting of cement, supplementary cementitious material, and aggregate; and c) incorporating at least a portion of the one or more concrete components into a reduced-carbon footprint concrete composition, wherein a cubic yard of the reduced-carbon footprint concrete composition has a carbon footprint that is less than that for a cubic yard of a conventional concrete composition, which conventional concrete composition comprises one or more conventional concrete components selected from the group consisting of cement, supplementary cementitious material, and further wherein determining the carbon footprint for the cubic yard of the reduced-carbon footprint concrete composition or the cubic yard of the conventional concrete composition consists essentially of the steps of i) multiplying the number of pounds of carbon dioxide per pound of the concrete component by the number of pounds of the concrete component per cubic yard of concrete composition to obtain a multiplication product; ii) repeating step i) for each concrete component in the concrete composition, resulting in one or more multiplication products; and iii) summing the one or more multiplication products to obtain the carbon footprint for the concrete composition.
 32. The method of claim 31, further comprising adding water to the reduced-carbon footprint concrete composition to form a settable composition.
 33. The method of claim 32, wherein the reduced-carbon footprint concrete composition comprises residual water from precipitating the synthetic carbonates, producing the one or more concrete components, or a combination thereof.
 34. The method of claim 33, wherein the residual water provides 5% of the water needed for the settable composition.
 35. The method of claim 33, wherein the residual water provides 20% of the water needed for the settable composition.
 36. The method of claim 33, wherein the residual water provides 50% of the water needed for the settable composition.
 37. The method of claim 31 or 32, wherein the synthetic carbonates are metastable.
 38. The method of claim 31 or 32, wherein the synthetic carbonates comprise calcite, monohydrocalcite, aragonite, vaterite, ikaite, amorphous calcium carbonate, magnesite, barringtonite, nesquehonite, lanfordite, amorphous magnesium carbonate, hydromagnesite, dolomite, huntite, and sergeevite, or a combination thereof.
 39. The method of claim 31 or 32, wherein the synthetic carbonates have a δ¹³C less than −10‰.
 40. The method of claim 39, wherein the synthetic carbonates have a δ¹³C less than −20‰.
 41. The method of claim 40, wherein the synthetic carbonates have a δ¹³C less than −30‰.
 42. The method of claim 31 or 32, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is at least 25% less than the carbon footprint of the ordinary Portland concrete composition.
 43. The method of claim 42, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is at least 50% less than the carbon footprint of the ordinary Portland concrete composition.
 44. The method of claim 43, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is at least 75% less than the carbon footprint of the ordinary Portland concrete composition.
 45. The method of claim 31 or 32, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is neutral.
 46. The method of claim 31 or 32, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is negative.
 47. The method of claim 46, wherein the negative carbon footprint is −250 lbs CO₂/yd³ or less.
 48. The method of claim 47, wherein the negative carbon footprint is −500 lbs CO₂/yd³ or less.
 49. A reduced-carbon footprint concrete composition produced by the method of claim 31 or
 32. 